Other Fuel System Pump problems of the 2005 Ford Expedition

Fuel pump driver module failed due to design flaw which caused galvanic corrosion. Aluminum body of component acts as the sacrificial anode for the frame which is steel. This caused my vehicle to stall at 65mph and lose power and thus caused the loss of power steering and hydraulic brake booster while traveling a high rate of speed. This could be especially dangerous on highways, congested areas, or areas with pedestrians such as schools. I have also notified Ford of this problem.

Driving up a small incline and the vehicle lost power. I had electrical power just no fuel getting to the engine. I was able to pull off to the side of the road. The fuel tank was just below a 1/4 tank. Add a gallon of gas and tried to restart the car. It would not restart. Called for the tow truck to take to the garage. The garage had to drop the fuel tank and told me the fuel pump control module was bad. They handed me the module upon picking up my vehicle and I can tell you why the module went bad. It has a hole in it from corrosion. I have said module if anyone from Ford or NHTSA would like to examine the module.

The contact owns a 2007 Ford Expedition. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer where it was advised that the fuel pump had failed. The contact was informed by the dealer that the repair would take three months because the fuel pump was on back order and there was no after market fuel pump that would work on the 2005 model year. The failure and the current mileages were 74,000.

While I was driving done the interstate, my Ford Expedition lost all power and completely stalled. Luckily, I was able to get it off the road to the shoulder without any incident. This is the third time it has happened to me. Previously, I had my fuel pump sensor changed because my check engine light came on and that is what it indicated; however, the problem still exits and my mechanics are baffled. Very dangerous!.

While traveling down the freeway at 70 mph, the vehicle died. It would not restart. After 1 hour vehicle the vehicle started and then died within seconds. The fuel filter and fuel pump were replaced because all indications lead to believe that the fuel pump was bad. After replacement of the fuel pump, vehicle would not start. Looking on the internet for possible solutions from others, I found one person with the same problem and followed their advise on how to fix it. I found the "drivers module" on the back topside of the frame. When the module was removed, it was found to have two large sections of corrosion about 1/4 inch thick. When the chunks were knocked off, under them were two holes through the side of the module and the circuit was burnt, the plug was also starting to corrode. The placement for the module is a terrible spot. It is aluminum attached to a steel frame, with nothing separating them. When the new module arrived, it now has a rubber gasket to keep them separate. This looks like a design flaw on Ford's part and a recall should be ordered. Ford should further refund the cost of the fuel pump because all indications show that the fuel pump is bad, when in truth it is the module and not the fuel pump.

The reported model was cruising at 65 miles an hour along north bound I-795 @ nc rte 42, wilson, nc (state police responded to this disabled vehicle call) vehicle acted like it ran out of gas. Electrical proveout indicators were normal. Ignition system was functional, as were all other facets of the electrical system seemed fine during the engine power failure, however , loss of steering power and braking power was evident and prominent. After safely coasting off onto the shoulder just past the said intersection the vehicle would not start and was towed to a repair facility. A final diagnosis was performed and was determined of a relay contact failure. This relay is an integral part of the main power distribution panel / fuse block right of the passenger foot well. Making this part integral to the power block makes it extremely expensive to repair and makes the vehicle unsafe as far as a reasonable repair to a critical system and places other systems at risk by the nature of replacing the entire power block to repair the problem. . The fuel pump. When this relay contact fails, power is lost to the fuel pump driver module located under the driver's rear wheel well. This module supply power to the fuel pump motor in the fuel tank. The fuel pump control module itself should be scrutinized hence it's location makes it vulnerable to weather and quick corrosion.

2005 Ford Expedition stopped running while driving at 40 mph in heavy traffic. Vehicle would not restart. It appears to be a fuel pump problem. Only 40,000 miles on this vehicle. None of the dash board light indicators came on.