Fuel relay bypass

ray young · Jun 10, 2019

hi, my fuel relay is going bad. i cant replace the fusebox right now, and i need to have the truck for job search. im looking for a fuse to tap into so i can bypass the relay . what fuse can i use? the couple i have tried have either killed the battery or the truck would keep running with the key removed. i was thinking of using the radio fuse. but what # is that?

thanks

Yupster Dog · Jun 10, 2019

ray young said:
hi, my fuel relay is going bad. i cant replace the fusebox right now, and i need to have the truck for job search. im looking for a fuse to tap into so i can bypass the relay . what fuse can i use? the couple i have tried have either killed the battery or the truck would keep running with the key removed. i was thinking of using the radio fuse. but what # is that?

thanks

See if this thread helps
https://www.expeditionforum.com/threads/fuel-pump.30013/

ray young · Jun 10, 2019

thanks yupster dog

geoffdaddy · Jun 15, 2019

Replaced mine about 5 months ago. It was pretty easy, if you have any decent soldering skills.

smartelbros · Jan 9, 2023

I'm not very experienced with soldering but im mechanically inclined is it to risky to give it a try? What's the chances I ruin something else?

whtbronco · Jan 9, 2023

Nah replacing the fuel pump relay is actually quite easy I thought. I did have buy a solder sucker, but they are cheap. I bought 2 relays and 2 solder suckers for under $20, so now days it'll be $30 probably. Took less than 2hrs to do the entire job.

Disconnect the battery and be 100% certain you have electrical flux and electrical solder. The acid in plumbing flux will eat the circuit board after a few weeks and ruin in. Aside from that nothing to be too worried about. There's instructions here and videos on YouTube.

Hamfisted · Jan 9, 2023

Once you break down the fuse box and get the circuit board out it's not a hard repair for someone with average soldering skills. The red number correspond to the numbers on a standard 5 pin general purpose relay. You can find the short harness on Amazon or some autoparts stores will have them.

5 pin relay and socket on Amazon

Here's the circuit board relay connection points once you get the old fuel pump micro relay out of the way.

Fuel relay bypass

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