Need fuse box help!

[jbarr73]

i have a 2003 5.4L eddie....i just replaced the passenger kick panel fuse box because the fuel pump relay burned up...i got an "new model" ford replacement fuse box and hooked it up with no problem i even replaced the power wire the came with the new fuse box. once all done it throw some codes for misfires and the engine has no pick up what so ever so i went back to double check my work and noticed the fuse box very warm. every thing is tight and grounded right. Any one have any clue what it might be??

 

[stamp11127]

Fuse boxes are not supposed to get really warm. Heat is a byproduct of current draw - so you have at least one circuit that is drawing more than it was intended too. You need to find out which one that is.

The old fuse box is repairable if you have soldering skills.

 

[jbarr73]

I understand that but any clue what circuit would cause that? everything works as it should other the stated engine problems. I had Zero problems with it till the fuel pump relay burned up and now this happens

 

[stamp11127]

Can't determine which circuit is drawing too much without being there. Touch each relay and see if one of them is the source of the heat. If so then you know which circuit the problem is on.
I would guess the fuel pump circuit would be the culprit since it cooked one relay already.

 

[Bedrck47]

Just a question Is the fuse box getting very warm while your driving or is it getting very warm when the expy is shut off

 

[jbarr73]

just while its running

 

[jbarr73]

Ok so i just did what Stamp said i went and started it and felt for which relay or fuse started to heat up....and its the fuel pump relay.... So what about be the common cause of this problem?

 

[Bedrck47]

How many miles on the expy? When did you last change the fuel filter?

 

[jbarr73]

145*** I have only owned it for about 2 weeks now so i have never had changed it yet

 

[Bedrck47]

Maybe the previous owner knew something that you didn't know

My suggestion would be to replace both the fuel pump and filter before you loose another fuse box

 

[stamp11127]

Usual causes for excessive current draw:
Poor connections
Corrosion in the wiring
Failing fuel pump
Low supply voltage

Two options - toss parts at it until you get lucky or diagnose it then replace or repair the problem. To diagnose you'll need a good dmm to check voltages in the circuit.
If you go the diagnostic route do you know how to use the dmm?

 

[jbarr73]

Well Money is a little short after buying that fuse box lol so ill start with the cheapest first lol

 

[jbarr73]

I have ordered an ford service manual should be here any day ill follow what the book says so i'm not just throwing money at it

 

[Bedrck47]

Do as stamp suggest and go the diagnostic route and I am sure you will find that the Service manual will say just about the same

But it is always nice to have the manual

 

[jbarr73]

Thank you everyone for the help!!

 

[Bedrck47]

another suggestion would be not to drive it until you get the problem resolved You don't need for the problem to cause you to replace another fuse box

 

[jbarr73]

its parked lol its not going anywhere

 

[Bedrck47]

When you finally find the cure to the problem.
Post the results as it may help others
Keep the forum updated

 

[Hamfisted]

Since you just got the Expy I would change the fuel filter too and see if that lessens the load on the fuel pump. A clogged fuel filter will cause all kinds of problems. After that you can put a amp meter in the fuel pump circuit and check for amperage draw. Or even do it before and after the new fuel filter install and compare the difference. Just get one of the mini-fuse testers off Amazon, they work great and they're easy to use. There's an adapter available if you already have a digital multimeter too.

Mini Fuse multimeter adapter

Fuse-Buddy-Mini-Tester .... Time limitations of 10 seconds under load....





-Mike

 

[jbarr73]

I just changed the fuel filter with little to no change. the fuel pump relay is getting warm and the engine is misfiring every now and then.