1998 Ford Windstar: fuel pump failure

Filed Aug 2, 2013 · Engine, Fuel system · 155,000 miles · SC

My windstar has about 155,000 miles on it and a 25 gallon tank. About six months ago it cut off on the interstate in front of a tractor trailer with my daughter driving. It had just traveled about 200 miles and it was raining hard. We had it towed to a ford dealer and all he reported was the fuel pump fuse blew. The second event was on vacation and after driving about 175 miles. Again it was pouring down rain. I figured it was moisture related and let it sit three days and the idle close to 1/2 hour. Finally I drove it about 45 minutes and it seemed fine so we drove home. Again at about 150 miles and heavy rain it blew the fuse about 5 miles from home. After two more fuses we made it home. I used an air compressor and air nibbler to carefully cut an access hole in the floor of the van. My daughters chrysler comes with an access point for fuel pump service. Now my van has one too. The original pump was in the tank. The wires exposed to fuel were chaffed in 5 spots and arcing at the push in connector. The arcing was due to a crimp on a hose clamp rubbing the wire near the push in pump connector. This rubbing may happen due to other stories I've read about where the tank collapsed from vacuum in the tank. Shame on the people who designed this pump, tank and the assembly process. By the way I'm a quality engineer at an engine factory. I expect a fuel pump to wear out -- not short out.

Filed Jun 29, 2005 · Fuel system · 80,900 miles · MI

Dt: contact stated the fuel sending unit and the fuel pump harness melted. Dealer told contact she was lucky the vehicle did not blow up on her. This happened while she was driving the vehicle. The check engine light came on, and then vehicle coasted to a stop.

Filed Feb 19, 2004 · Electrical · 44,500 miles · PA

The fuse in the fuel pump blew out on three separate occasions. When this occurred the vehicle stalled. Upon replacing the fuel pump, the consumer checked the wiring in the fuel pump. They noticed that the wires were rubbing against a metal clamp or pipe , which caused the installation to rub off. *nm

Filed Feb 13, 2004 · Fuel system · 142,271 miles · WA

Fuel tank collapse on 1998 windstar dealer wants $1300 dollars to replace fuel tank and all related components. Dealer says this is because there is a vacuum inside tank created by the fuel pump. Perfectly running van that has been kept up maintenance wise is now inoperative do to stalling.

Filed Jan 15, 2004 · Fuel system · NJ

Fuel pump fuse has blown on 1998 ford windstar. *mr the vehicle ceased to run while in heavy traffic. The consumer found that it ha been a number of vehicle's with fuel pump wire failures due to defective venting systems for the fuel tank. This causes the fuel tank to deform, collapse and pinch the wires to the integrity mounted fuel pump.

Filed Jan 15, 2004 · Brakes, Engine · 84,000 miles · NY

Head gasket failure. Faulty head gasket design in my opinion ABS/traction control unit. Current problem tsb states that fuel tank manufactured with incorrect depth - fuel pump wiring is rubbed until electrical short occurs - and fuel pump fuse blows - vehicle is then stuck in traffic, in the middle of an intersection etc. Fords recommended fix is to replace the fuel tank and pump assembly however, they will not contribute anything to the cost of the repairs caused due to their faulty design.

Filed Jan 6, 2004 · Fuel system · 95,000 miles · OH

While driving at various speeds and without warning consumer smelled gas fumes inside the vehicle. Cause has yet to be determined. *ak the seal between the gas tank and the fuel pump failed because the gas tank collapsed. The gas tank was replaced at the dealer. The fuel gauge accuracy problem that was corrected when the new gas tank was installed.

Filed Nov 6, 2003 · Fuel system · 84,554 miles · NY

Vehicle blows fuel pump fuse and stops running. This has occurred in 3 instances on the highway and in the middle of an intersection.

Filed Oct 1, 2003 · Fuel system · 50,000 miles · OH

I have a 1998 ford windstar, and its fuel tank was leaking into the passenger compartment. When brought to the dealer it was said that the fuel tank collapsed at the fuel pump, which caused the leaking.

Filed Oct 17, 2002 · Fuel system · NH

our fuel pump went for a second time in a three month period. The cause of the fuel pumps malfunction was a short in the wiring which was caused by the fact that the depth of the fuel tank was not within the required specifications. The depth of the fuel tank was only 6 5/8" deep. If the depth of the tank is to shallow, the wiring atop the fuel pump can become chaffed on the metal fuel hose clamp. Ford had issued a service bulletin on this very issue. What occurred with our van was precisely what the service bulletin warns of. The service bulletin states that if thefuel tank depth is less than 7 3/4" replace the fuel tank 9002 and fuel delivery module 9h307. our van clearly met that criteria, however, ford would not replace the fuel pump or fuel tank at fords expense. The service manager and technician at ford stated that if I were a regular customer of duddie ford, that they would not let me take the van with me because of the safetyissues involved. When I asked what exactly they meant, they stated that because of the chaffing of the wiring on the fuel pump, a short could occur, which could ignite gasoline fumes and therefore result in a catastrophic tragedy. Basically, the van could explode. An appointment was made at granite ford in rochester, new hampshire for replacement of the fuel tank per the service bulletin. The granite ford technician also measured the depth of the fuel tank and found a depth of only 6 5/8". (see granite ford invoice) the fuel tank was removed and replaced. Dt

Filed Aug 19, 2002 · Fuel system · UT

Fuel pump has stopped working due to insulation on wires wore off, which in some cases could result in a fire. Contacted dealer.

Filed Aug 19, 2002 · Fuel system · KS

There are wires going through fuel tank that have no cover, and it could cause a fire. Dealer notified. *ak the vehicle had stalled several times due to wires shorting out in the fuel pump. The fuel pump was replaced. Yh