2004 Ford Expedition fuel system problems

Filed Dec 2, 2020 · Electrical, Engine · 158,612 miles · TX

Vehicle lost power for 3-5 seconds at highway speeds approximately 65 MPH on three separate events. Vehicle slowed down due to power loss while in heavy traffic. Three other times at idle speed in drive and in park engine stalled and immediately restarted. Loss of power steering due to engine not running when stall event happened. I performed inspection of fuel pump relay which is internal to passenger side fuse block. Found inadequate solder joint on integrated relay printed circuit and burn marks on outside of fuel pump relay. Located salvage fuse block same make and model and inspected. Same damage on salvage fuse block assembly. Replaced with aftermarket fuse block with revised solder joint and updated relay.

Filed Jun 9, 2020 · Electrical, Fuel system · CO

The gas gauge never works and sometimes the vehicle thinks that it doesnt have gas when it does.

Filed Sep 25, 2019 · Fuel system · 180,000 miles · TX

Tl* the contact owns a 2004 ford expedition. While driving various speeds, the vehicle suddenly stalled and shut off. Later, after restarting the engine, the vehicle operated normally. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump relay circuit board had malfunctioned and burnt out. The circuit board was replaced and the failure was remedied. An unknown local dealer was contacted. The manufacturer was not contacted. The failure mileage was 180,000.

Filed Sep 10, 2019 · Electrical, Fuel system · TX

While driving a 2004 ford expedition 178,000 kept stalling on the highway and streets. I had it towed several times because it won't start back on the next day it would turn on. Had the fuel pump replaced and still having the same problems it turn off on my 18 year old son like 5 times going to school and work where it almost got to the point where we felt it wasn't a reliable due the fact it stalls while on the road or even just turning and almost caused my sons life . Finally we found out it's the relay gets hot and it causes for the car to stop and I'm aware that ford knows about this very frustrating and disappointing they have not done a recall on this the relay can not be change by its self has to be the whole circuit board

Filed Dec 31, 2018 · Fuel system · 188,000 miles · VA

Tl* the contact owns a 2004 ford expedition. While driving 60 MPH, the vehicle stalled without warning. The contact was able to restart the vehicle after waiting several minutes. The vehicle was taken to cowles parkway ford (located at 13779 noblewood plaza, woodbridge, va 22193, (703) 986-5500) where it was diagnosed that the fuel pump needed to be replaced. The vehicle was repaired, but the failure recurred a day later. After further research, the contact became aware that the fuel pump relay needed to be replaced. The vehicle was not repaired. The manufacturer was contacted. The approximate failure mileage was 188,000.

Filed Dec 19, 2017 · Fuel system · 186,000 miles · VA

The vehicle shuts off while driving (at any speed) and often without warning. In addition, the vehicle may also not start at all then start without explanation. The most common recommendation is to replace the fuel relay. To do so, you must replace the smart junction box/fuel relay panel. This appears to be a common problem with numerous mentions and is often difficult to diagnose and commonly becomes a process of elimination. The biggest concern is the safety issue and odds of accident or fatality. Diagnoses typically requires complete failure because the symptoms can rarely be duplicated. This has happened frequently with complete failure happening. Hardwiring the fuel pump rules that out. Fuel relay is found to be hot to the touch.

Filed Oct 23, 2017 · Engine, Fuel system · CA

the federal safety agency ID #10017888/10018745/10023943/10004051/10010731/10012977/#10014086/10018069/10014100/10028736

Filed Sep 22, 2017 · Fuel system · 125,000 miles · CA

Multiple and intermittent engine stoppage. The engine stalls suddenly while driving in traffic causing hazard to self and others. Sudden loss of power steering makes control of vehicle difficult as power steering is non functional as you attempt to pull to the side of a busy road. Braking systems also are mostly non functional without the vacuum created by the running engine making it very difficult to stop quickly. This presents a dire emergency condition for the surprised driver, and a hazard to other occupants as well as other drivers nearby. A driver who is small in stature may be unable to man-handle the stiff steering condition. Once stopped, the engine may restart right away or not, stranding occupants in unsafe conditions and cause an accident chain involving life and death. Fuel pump relay failure is the cause and very common, (100s of thousands of posts online about this problem). This problem affects these expedition vehicles in a widespread fashion similar to the lcm safety issue with another ford product, the crown victoria. (a recall was ordered on this issue for some of the model years) this has happened to me 8 times in 3 weeks since owning this 2004 vehicle. It is currently at the ford dealer who state they may need to keep the vehicle for up to 3 weeks to observe the failure mode. (it is intermittent)

Filed Sep 21, 2017 · Electrical, Engine · CA

Tl* the contact owns a 2004 ford expedition. The contact stated that the vehicle randomly stalled at any rate of speed. The vehicle was able to restart. Two dealers (downtown ford, 1‑866‑899‑7296) and (future ford of sacramento, 916‑547‑2285) were unable to replicate and diagnose the failure. The vehicle was not included in the federal safety agency action number: dp5005 (engine and engine cooling). There were nine tsbs for engine and engine cooling, two tsbs for the fuel system, and thirteen tsbs for the electrical system. Neither dealer provided diagnostic testing. The manufacturer was notified of the failure. The failure mileage was not available.

Filed Jul 20, 2017 · Electrical, Fuel system · 124,000 miles · WA

When driving home from seattle wa. To walla walla wa. At a speed of 70 MPH the vehicle died and I had to get off the road, it then restarted and did it to me 3 more times. When I took it to the shop the mechanic stated that it was in the fuse box. He had just did a replacement on the same type vehicle that had caught fire. It is the fuel relay in the fuse box that malfunctions and catches fire. I feel this is a safety issue.