I had a simular problem with my 2003 expedition 5.4. What it turned out to be the pick up tube had a hole in it from rubbing against the fuel pump assembly. I replaced the whole assembly and have not had anymore problems. The replacement part has a protective sleeve over the tube.
Same thing happened to me. The PCM relay went bad. Replaced relay and truck starts fine. Before I replaced relay I completely dismantled fuse panel and looked at the circuit board. There were no problems with board just a small melted spot in plastic near where the pin touches . Hope this...
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