2004 Ford Expedition: fuel pump failure

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 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 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 Jul 5, 2017 · Engine, Fuel system · 169,900 miles · CA

Tl* the contact owns a 2004 ford expedition. While driving approximately 75 MPH, the vehicle lost power without warning. The vehicle was pulled over to the side of the road and towed to an independent mechanic who diagnosed that the engine did not get fuel from the fuel pump. The technician recommended that the fuse panel be replaced. The manufacturer was made aware of the failure and stated that there was no recall. The vehicle was not repaired. The failure mileage was 169,900.

Filed Jul 2, 2017 · Acceleration, Electrical · 190,000 miles · SC

My vehicle, without any warning at any speed, including highway speeds, shuts off completely,without any warning or indication that it is about to do this. Always on a straight road with almost a full tank of gas. The cause a relay switch which is soldiered into the memory board that controls the vehicle's brain box that shorts out. After doing research on the internet, I am both shocked and disgusted that the nhsta has not investigated this faulty design by ford and made them recall all of the 2003- 2008 expeditions. You only have to pull it up on you-tube or google to see the 1000's upon 1000s of complaints from expedition owners concerning this constant and dangerous problem, which clearly endangers every expedition owner and their family. The worst part of this, the ford dealerships want you to spend $1000 of dollars needlessly to try and diagnose this same, old problem, before they finally deal with replacing the entire fuse block panel, just for the relay switch, which is the cause, the shorting out relay switch. The internet shows again and again, that this problem is so rampant, that it isn't if it happens, but when, because it was a faulty and defective design, which endangers all expedition owners made these years. The faulty fuse block's fuel pump relay switch burns out and between that and the thin wires grounding out under the hood, drivers, unsuspectingly are left in panic modes on the highway, scrambling to get out of harms way, as a result of your vehicle turning off at all speeds, ie, 70 MPH. Imagine a semi is behind you and you don't have the safe means of escaping the dangerous predicament you are now left in to get over to the side of the road? A recall is needed asap before too many people are needlessly killed as a result. Expedition's are family vehicle's and usually have lots of children in them! This is too dangerous to keep overlooking.

Filed Feb 25, 2016 · Electrical, Fuel system · 126,000 miles · WV

Tl* the contact owns a 2004 ford expedition. While driving at various speeds, the vehicle stalled without warning. The vehicle was restarted and taken to a dealer and an independent mechanic; however, the cause of the failure was unable to be determined. The contact mentioned that the alternator, battery, transmission, fuel pump, and fuel bypass switch were replaced; however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 126,000.

Filed Jun 4, 2015 · Electrical · 100,000 miles · NJ

I am the 2nd owner of this vehicle. Had problem w/ drivers seat & mirror fuse blowing out since I purchased truck in august 2011. Some time in 2012 I started having additional problems w/ my truck like radio &/or heating/air not coming on when started. Check engine light going on & off & back windshield wiper stopped working. Then it was the vehicle was dying quickly by leaving the radio on for 10 min after vehicle was turned off. We replaced the battery & terminals that connect at the positive & negative. We had plenty of other issues like the entire brake lines needing replacing due to rusting. There is now rusting on other parts of the truck. Blew fuse to air conditioner 2x. Things seem to be ok after battery was replaced until the truck shut off several times while driving it over the past year. Sometimes if you waited 5-10 minutes it would restart. Vehicle has been in shop & nothing comes back on diagnostic test. We have had the alternator & fuel pump tested. The cables to the battery were just found rotted & replaced but something is still killing my battery. The fuse box has been making loud click noises when the truck struggles to start. Today it wouldn't start again until jumped & now the radio wouldn't go on. At the shop again & the mechanic is stumped but working on it! From research it seems to be either a fuel pump relay that is apparently sodder into the fuse box & almost impossible to replace w/ replacing the whole box or it is the fuse box itself. I am also seeing claims of water leaking down windshield & getting into fuse box. All I know is ford should acknowledge & recall before someone gets killed! My children were in the car several times now when it staled while I was driving or stuck in parking lot & even a severe thunderstorm when it won't start. And now I'm reading the fuse box has caught fire in some of these cars! I rely on this vehicle!

Filed Jul 31, 2014 · Engine, Fuel system · LA

The first incident with my ford while driving at about 25mph the spark plug was blown out. Ihad the spark plug issue repaired. My second issue with my ford now is that it shuts off while driving at speed. It has happen 4 times now. I have read some blogs that state it might be the bad placement of fuel pump driver module or fuel pump relay. This may cause a crash. Please research!!!!

Filed Jul 18, 2014 · Fuel system · 120,000 miles · WA

4 separate times my 2004 expedition has died while running down the road, one time it died in a very dangerous spot (blind s-curve with no shoulder). It always seems to restart after it has cooled down after a while. This last time we tried multiple things to get it running because it was stuck at a busy intersection and it was over 100 degrees outside, but nothing we did helped. I ended up getting it towed to a shop who told us it needed a new fuel pump ($1100). We decided to take it home, and thank goodness we did. After charging the battery it started right up. We have research this problem and it seems to happen to many expeditions and ford pickups. It looks like this has caused many people a lot of money and has left them stranded many times. From our research it is probably the fuel pump relay (r303) or the fuel pump driver module (if it has one). Unfortunately our exp. Has the relay instead of the module making it harder to replace. I would like to know why their hasn't been a recall on the relay or module!!! I am very thankful my children weren't with me when I was left stranded with the temp above 100 degrees out. Something needs to get done before someone gets hurt!