Is this the fuel pump fuse box issue?

[SteveP]

Hello all,
2003 Eddie Bauer edition. Has been running fine. Was running some errands today. At the third store I stopped at, got back to the car and cranked the motor, it rough idled like really low RPMS, maybe 300-400RMPs and die if I gave it any throttle. I kept trying maybe 5 or 6 times, if I left my foot off the gas it would run longer, maybe 10-15 seconds, but if I gave it any gas it died. Tried starting it with foot off the gas, and all the way floored. Same symptom. Opened hood and checked for disconnected vacuum lines etc, nothing looked out of the ordinary. Called AAA, tow truch driver asked me some questions, had me try to start it said he didn't hear the fuel pump and said its probably the fuel pump. Towed it home and he went to start it to see and it started right up. I have been able to start it just fine a couple more times. But of course now I am hesitant to drive it anywhere (and was going to go on a roadtrip to see family this weekend). But now that it is working, I am not sure what to check or if its possibly the fuel pump about to die, or the relay or fuse box on its last leg? Thanks in advance. Kind of stressful since we were going to drive this with dogs, presents kids etc.

 

[whtbronco]

I had the same symptoms when my relay burned up. When the fuel pump failed I had a little warning that morning and on my way home from work. I made a stop at a doctors office and it would start again. I would not take it on a trip until this is resolved. I wouldn't even have taken mine to work, but a 70 mile cab ride wasn't happening.

If the relay is cooked you'll be able to smell it, at least I could. The central junction box(fuse box) is at the passenger front kick panel. This is what I would check first.

This is the authoritative thread on the fuse box:

Another fuse box replacement ....

Just replaced my '03's fuse box again. The second fuse box was installed in January 2014 due to the typical melted fuel pump relay and PCM relay. It was manufactured in November of 2013 but still had the old 15 amp Osram fuel pump relay and other micro relays just like the original '03 fuse box...

www.expeditionforum.com

You might be able to get a new relay to solder in or an entire fuse box by the weekend, but that's a long shot since it will almost certainly have to be ordered online. It doesn't take long to swap out though. The fuel pump would take a mechanic a couple hours, it's about 3hrs book time, but a replacement is likely available from a local parts store.

 

[SteveP]

I had the same symptoms when my relay burned up. When the fuel pump failed I had a little warning that morning and on my way home from work. I made a stop at a doctors office and it would start again. I would not take it on a trip until this is resolved. I wouldn't even have taken mine to work, but a 70 mile cab ride wasn't happening.

If the relay is cooked you'll be able to smell it, at least I could. The central junction box(fuse box) is at the passenger front kick panel. This is what I would check first.

This is the authoritative thread on the fuse box:

Another fuse box replacement ....

Just replaced my '03's fuse box again. The second fuse box was installed in January 2014 due to the typical melted fuel pump relay and PCM relay. It was manufactured in November of 2013 but still had the old 15 amp Osram fuel pump relay and other micro relays just like the original '03 fuse box...

www.expeditionforum.com

You might be able to get a new relay to solder in or an entire fuse box by the weekend, but that's a long shot since it will almost certainly have to be ordered online. It doesn't take long to swap out though. The fuel pump would take a mechanic a couple hours, it's about 3hrs book time, but a replacement is likely available from a local parts store.

Awesome thank you! I found some relays on Amazon for $11, just need to see how fast they can get here https://www.amazon.com/gp/product/B0B7494SG7/. I used to solder all day for work installing car audio and security systems so the soldering won't be hard. I just didn't want to start replacing parts one at a time whack a mole style. Thank you for the link!

 

[whtbronco]

Then you will know better than to make the mistake I did. I accidently grabbed my plumbing flux and 6 weeks after I replaced the relay the board delaminated, oops.

Just make sure that's the issue before hanging your hat on it. As noted I could smell it burnt, but I could also see the plastic housing melted slightly before pulling it out and finding the toasted relay.

 

[SteveP]

Then you will know better than to make the mistake I did. I accidently grabbed my plumbing flux and 6 weeks after I replaced the relay the board delaminated, oops.

Just make sure that's the issue before hanging your hat on it. As noted I could smell it burnt, but I could also see the plastic housing melted slightly before pulling it out and finding the toasted relay.

OK, so update, ordered the 2 relays that I linked. When they arrived I took my fuse box out and took it apart. When i had the board out, I smelled it, it smelled ok. I looked at it and visually it looked ok. But, i decided as I had the new relays and I already had it that far apart to just replace the relay anyways. So I did, which was pretty easy. Once I had the old relay out I decided to open it up. Which was impossible with out destroying the cover. I basically used small flush cutters to cut away the plastic housing. Once I had it open it still looked OK, but I couldn't really see the contacts since they were kind of sandwiched. So I cut the copper piece that holds it all together, then visually inspecting the contacts 2 of them had some bad arcing damage so when testing with my multimeter I was getting odd readings on part of the melted metal. So it looks like it was kind of working as long as the contacts touched in the right spots but every once in a while the contacts would touch as to not make a solid connection. I tried to take a pic but my phone would not focus on that magnification. I may try to take one with my little digital microscope I use for soldering when i get a chance.

 

[whtbronco]

Isn't that interesting. Sounds like you found a fault and hopefully the only fault.

Have you had a chance to test it out?