03 5.4 won't stay running

[CowboyTrukr]

My son-in-law has an '03 w/5.4. Just quit on them last Friday.

Replaced the burned up fuel pump relay. Would like to slap the engineer and their manager who allowed that garbage design. What a POS!

Also replaced the fuel pump. Pressure checked perfect at 55psi key on and also after trying to start. Dies immediately after starting just like a security system shut down would do, but it has no such item. Bled the fuel line completely so there's no air, but no start. I aplologize if this has been posted here and I missed it, but we need help. Thanks in advance.

 

[Hayes Riviere]

Any codes?

 

[Bedrck47]

Can you check the fuel pressure and monitor it while trying to start to see if it drops off and is causing the engine to stall

 

[CowboyTrukr]

No codes and pressure is constant. Won't stay running long enough to make that assessment.

 

[Bedrck47]

I am going to post some info on here shortly Stay tuned

 

[Bedrck47]

 

[Bedrck47]

Look at this video Pay attention to the dark green/yellow wire he is pointing to at the 6:10 minute mark in the video.

Directly to the left of his finger in the other connector you will see a RED wire. What I would like for you to do is to place a jumper between the dark green/yellow wire and the red wire. (A paper clip works.) This will jumper the contacts in the Fuel pump relay. This is a safe procedure and I have done this many times to help others on this forum

 

[CowboyTrukr]

Thank you, Sir. I watched that video the other night. The crazy thing is that the fuel pump stays running even after the truck shuts off. I'll have him try with the paperclip jumper

 

[Bedrck47]

Check the attached

http://www.expeditionforum.com/threads/97-ford-expedition-p0232.32930/

 

[CowboyTrukr]

Update: Son-in-law went and bought a salvaged fuse panel for $13 at the local u pull it. Replaced one missing top mounted relay and fired it right up. Apparently there was another failed relay on the original panel that I didn't find over the weekend.

All in, he spent $18 on a cam sensor (not the solution); $13 for the fuse panel (ultimate fix), and $74 for a new Delphi pump (needed to be replaced anyway).

Thank you all for the help.

 

[Bedrck47]

Your welcome

He got lucky with the fuse panel. Ford used 2 different fuse panel in the 03 model year

 

[CowboyTrukr]

That's good to know. Thank you so much!

 

[CertusExpo]

Okay... last update was in 2011 but here goes.

2003 EB 5.4 2WD w/170k miles and most possibly the stock fuel pump.

Came to a red light and she idled just fine until I pressed on the accelerator when she just shut off. No noise, no CEL, no indication of what was about to happen. I immediately cranked her and nothing. Cranked her a second time and she came to life and I drove away. I drove about 20 miles and no issues.

About two hours later when I left that location I began to drive home I was cruising down the highway at 70/75MPH when suddenly, just like before, she just went silent. No pops, no noises, no CEL was thrown and I even have an ODDII reader that links to my tab with the Torque app and not a single indication of anything from that.
I pulled to the shoulder, sent my son a text advising him that I was dead on the side of the highway but would give her a few minutes and try again before he came out to tow me the rest of the way home.

I tried cranking her a few times to no avail with the exception of once or twice when she kinda wanted to start but didn't. About 10 minutes later, I turned the key and Vrooooom. I threw her into Drive and made like the wind towards home. I made it home no worries, no sputters and no further issues.

My gut instinct drove me to research Fuel Pump and Relays which is why I'm here.


Anyone have any ideas or think I'm on the right path? I suppose my first steps would be to check fuel pressure and the output on the relay.

Thank you in advance for any ideas or assistance.

Edit: I believed I smelled something like insulation burning but as I was on the highway, I couldn't isolate it.

Edit 2: Found that the fuel filter cover was missing and the fuel filter has been flopping around for who knows how long.