Engine stall at speed- no code

[Rockclutch]

04 EB 5.4 2v

Engine cuts as if no fuel, but able to restart after shutting off ignition.
No fun on the freeway.

Completely random.

Fuel pump taking a nap?


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[1955moose]

Could be. What year/engine? Always post that. If it's an 05-06, look at fuel pump driver module up near spare tire. Do a fuel pressure test also. Pressure should be 28-45 running . Do you have a hard time starting after shutting off for more than 5 minutes? Let me know.

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[Rockclutch]

Thanks Moose

2004. 5.4L 2v
120k mi

Sorry for not adding that.

No trouble starting, but occasionally rough idle at stop lights.



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[1955moose]

2004 doesn't have the fpdm, so rule that out. Do the pressure test, and run a dtc codes test. You might have other problems. The 03/04 are famous for the fuel pump relay soldering come loose. That also is an area to check.

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[Rockclutch]

Yeah, I suspect the infamous fuse box issue may be at play here. This has been an intermittent issue for the last couple of years, maybe 6 times total in 40k miles.

Truck is really in great shape and usually trouble free.

I'll get under it and start testing when my northern California ground dries up a bit.

Amazing amounts of rain this year....maybe I just need a boat.

Thanks for the input, I'll report back my findings.

Cheers

Roc

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[1955moose]

Where you at in California? I'm in Daly City, just south of SF.

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[TobyU]

I'm a Town Car guy so please tell me about this infamous fuse box issue.
I have an 03 Navi and have to keep an ear open for potential probs.
I did have a sunroof leak that was running toward and by the gem I think they calll it at the passenger side foot area but no water on mine.

 

[1955moose]

Toby, no Gem past 02. 03 went to the single box in the passenger kick panel. They started soldering in the relays in 03. The fuel pump relay is the one where it causes the stalling problem. Best bet is resolder your old connections, the replacement ones are trouble. They didn't make just one for 03, and 04. Members here that tried a replacement one, always seems to have problems after.

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[Rockclutch]

Wow, Moose, I'm here in 'sunny San Jose', we should meet up sometime.

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[1955moose]

Sounds good. I'll have to let you know when I'm heading south, or you North. We'll have a couple of cocktails at my Lake. Shoot me a pm, I can give you phone #.

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[R0cketMan]

I had the same issue in my '03. I'd have the cruise control set on the highway then the engine would cut out. Cruise control sent the pedal to the floor, no check engine lights. I'd have to put it in neutral then restart. Turned out to be the fuel pump relay in the passenger side fuse box. The relay had a hole in the side of it. Infamous problem because Ford used a 10amp relay (Omron part number F8VF-BA). I bought a 30amp replacement that was used in the updated fuse panel assembly (Omron G8QN) from eBay for $9 and soldered it in myself. Saved me $400 by not needing to buy the whole fuse panel from Ford. I haven't had an issue since I put the new relay in! Fuse panel can be removed in 30 minutes. It's a good quick check if you've run out of other options.

 

[Jeremy Williams]

This may sound silly, but did you check the battery cables? I had the same problem on my expy and it was corrosion on the cables. Same thing happened to a friend in his Nissan SUV... I cleaned up the terminals and no more issues.

 

[Old Guy]

Remove the negative battery wire for 5 minutes. That may erase any glitches in the microprocessor. Tghen reconnect it and road test.
When's the last time you changed the fuel filter?

 

[1955moose]

A 10 amp fuel pump relay? I didn't think they made relays that small.

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[Rockclutch]

I had the same issue in my '03. I'd have the cruise control set on the highway then the engine would cut out. Cruise control sent the pedal to the floor, no check engine lights. I'd have to put it in neutral then restart. Turned out to be the fuel pump relay in the passenger side fuse box. The relay had a hole in the side of it. Infamous problem because Ford used a 10amp relay (Omron part number F8VF-BA). I bought a 30amp replacement that was used in the updated fuse panel assembly (Omron G8QN) from eBay for $9 and soldered it in myself. Saved me $400 by not needing to buy the whole fuse panel from Ford. I haven't had an issue since I put the new relay in! Fuse panel can be removed in 30 minutes. It's a good quick check if you've run out of other options.

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Hey there!
Late thanks for the details!
I finally got around to this today and was relieved both when I saw the condition of the relay was as expected (hole blown through the side) and upon hearing the engine roar to life after completing the job.

As always this forum saved my bacon and a good chunk of change!

Thanks again!

Fil

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[Andrew-XLT-Ford]

I have been having same issues that all started 2 weeks after my tranny rebuild. (May-2019) found my Negative battery terminal loose. but pulled the fuse panel to check, and the relay was fried, with a hole in the side. So far, i replaced my fuel filter, the relay, then the fuel pump... 3 weeks ago, now having same issues... Going to pull the panel again and re-check the board tomorrow.

Does anyone know if a crank sensor could cause an engine shut down while driving?
Only because it is located near the front drive shaft which has to be removed to remove the transmission.

 

[Hamfisted]

The crank sensor is kinda buried behind the AC compressor. I don't think any work done on the front driveshaft would interfere with the crank sensor. A bad crank sensor will kill the engine but will usually throw a DTC code ( P0335 ...). Whereas the fuel pump quitting will not.

But here's a good YouTube video that 1A Auto put out on the Ford sensor if you're curious: