Other Fuel System Pump Problems of Ford Expedition - part 1

This SUV stalled on the highway while driving in traffic. It was caused by a fault in the fuel pump or fuel pump relay. Please recall this vehicle.

See all problems of the 2003 Ford Expedition 🔎.

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.

See all problems of the 2004 Ford Expedition 🔎.

Vehicle suddenly stopped operating while driving 90 mph. A complete loss of power occurred. The vehicle was immediately put into neutral and allowed to coast so that it could be safely moved to the emergency lane of the interstate. Several attempts were made to restart the vehicle while coasting. Additional attempts were made to restart the vehicle after the vehicle came to a halt. No success. The vehicle would turn over but never start. The vehicle was towed to the nearest Ford dealer. After inspection, Ford determined that the fuel pump had failed unexpectedly.

See all problems of the 2016 Ford Expedition 🔎.

Several stalls followed by crank no start conditions over several months with no associated check engine light, code p0627 while vehicle in motion. 4m auto service center abilene TX performed fuse 27 relocation to fuse 73 accomplished. Vehicle returned to service. Several stalls followed by crank no start conditions over several months with no associated check engine light, code p0627 while vehicle in motion. Code cleared, vehicle returned to service. Stalled followed by crank no start conditions with check engine light, codes p025a, u0109 and p0627 while vehicle stationary. 4m auto service center abilene TX replaced fuel pump control module. Vehicle returned to service. Several stalls followed by crank no start conditions over several months with no associated check engine light no codes. Vehicle owner replaced fuel pump due to burnt wire (see attached photo). Vehicle returned to service. Contacted 4m auto service center, arrow Ford abilenetx aand Ford motor company customer service.

See all problems of the 2013 Ford Expedition 🔎.

Tl-the contact owns a 2008 Ford Expedition. The contact stated that while the vehicle was in the parking lot, the contact attempted to start the vehicle without warning as the vehicle stalled. Geico insurance was contacted and towed the vehicle to the dealer gaudin Ford 6625 w roy horn way, las vegas, nv 89118 (702) 534-3094 where it was diagnosed and determined that the fuel pump failed and needed to replaced. The vehicle was repaired. The manufacturer was contacted and informed the contact that 0 recall shown under the VIN. The failure mileage was approximately 65,000. Ck.

See all problems of the 2008 Ford Expedition 🔎.

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.

Tl- the contact owns a 2004 Ford Expedition. The contact stated that while driving at various speeds the vehicle would suddenly stall and shut off. Later after restarting the engine the vehicle would operate as normal. The vehicle was taken to an independent mechanic who diagnosed that the fuel pump relay circuit board had burned and malfunctioned. The circuit board was replaced and the failure was remedied. The local dealer(unknown) was notified of the failure. The manufacturer was not contacted. The failure mileage was 180,000. Jft.

Tl-the contact owns a 2004 Ford Expedition. The contact stated that while driving at 60 mph without warning the vehicle stalled. The contact was able to restart the vehicle after waiting for several minutes. The vehicle was taken to cowles parkway Ford located at 13779 noblewood plaza, woodbridge, va 22193, (703) 986-5500, to be diagnosed. The contact was informed that the fuel pump needed to be replaced. The vehicle was repaired however, a day later the failure recurred. The contact stated that 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 and informed of the failure. The approximate failure mileage was 188,000. Ah.

"takata recall" I was driving down the interstate at 65 mph when my truck just cut off, had to have it towed in to the shop. Had fuel pump replace, 2 weeks later same problem. Had to have it towed again fuse was replace. 3 weeks later I'm now having to have the fuse box replace. Ford motor company don't think this should be a recall issue. They just came out with the latest update fuse box in 2017.

Customer complained of the vehicle stalling. Testing found an electrical issue with the fuel supply and delivery system. Removal and inspection of the fuel pump found the internal power wire to the pump rubbed through on the pressure regulator ground spade causing a short circuit inside the fuel tank - this short circuit blows fuse 44 in the underhood fuse box, causes the vehicle to stall without warning, melted the safety ground wire between the fuel pump and pressure regulator, and has a high chance of causing a fire inside the gas tank. This was on the factory oe motorcraft fuel pump assembly.

See all problems of the 2012 Ford Expedition 🔎.

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.

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).

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.

See all problems of the 2005 Ford Expedition 🔎.

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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.

The vehicle would not start. After diagnosis we found the fuel pump which in located inside the fuel tank had burned and melted at the wire connectors. Had the fuel been lower and the wires exposed the fumes would have exploded. This is a very dangerous and a recall should be issued before someone dies from a fire. The fuel tank is also located directly under the left side seats.

See all problems of the 2007 Ford Expedition 🔎.

The engine stops running without warning. I was driving on the freeway at 70+ in heavy traffic. All of a sudden the engine shuts down. I put the vehicle in neutral and engaged the flashers. I tried to restart the vehicle while maneuvering to the side of the road avoiding multiple close calls. Once stopped, I put the vehicle in park and tried to restart. After a couple of minutes the car restarted. I took the vehicle to the autozone to see if there were any fault codes. One code indicated the fuel pump was an issue. They advised me that they have seen this before and directed me to go to the dealership. The dealership could not look at it immediately so I had my son pick me up with another vehicle. The following day they ran a diagnostics ($95 fee that was totally unnecessary since this is a well know failure) on the car and indicated that it was the faulty central junction fuse box located inside the vehicle on the passenger side near the feet. Pn 3l1z-14-a068-aa-a11 @$517. Installation costs $215. When I got home I searched the web and found that this is a common failure for this vehicle. The blogs and comments are of multiple near missed collisions among other things. This part failure happened on vehicles that were less than one year old. It can happen at anytime to any 2003 Ford Expedition. This part was redesigned for later Ford Expeditions because Ford knew of the problem. If you contact any pick and pull salvage yard you will find that all of these central junction box (fuse boxes) are not available since everyone tries to replace them by themselves because of the high costs. Also, there are multiple companies that will repair the faulty part with a re-engineered circuit. Ford has since made a new part with a different pn / model number. This should have been a safety recall in the first year. It is very dangerous and lives are at stake.

Fuel pump relay shorted out in motion. Highway and city streets. Steering locks up engine just dies in motion. Super dangerous and scary replaced fuse box and same thing happened again. No power steering engine just dies in motion. So scary on highway 75 mph.

The contact owns a 2008 Ford Expedition. While driving approximately 50 mph, the engine shut down without warning. The vehicle failed to restart. A policeman pushed the vehicle to the side of the road. The vehicle was towed to the contact's residence. The fuel pump was replaced and the vehicle was repaired. The manufacturer was notified. The approximate failure mileage was 103,000.

The vehicle will randomly shut off at any speed, under any condition. Engine dies unexpectedly at highway speeds creating a panic to get out of the roadway. Power to steering and brakes are gone when the engine dies. Vehicle will restart after a couple minutes. The faulty part is the fuel pump relay. It is integral to the fuse box and cannot be changed without changing the entire fuse box. The fuse box is only available from a Ford dealer for $485. 20 parts only.

I left to go grocery shopping around noon this March. About 15 min. Into my drive going up a hill on a highway and right after passing a car that was doing about 50 in a 70 mph zone, my car just died while topping the hill. I had no power steering, and no breaks. Thankfully I have had car with out power steering and knew it was going to be tough to get it on the shoulder before being hit by the semi that was behind me. It would not start or do anything after that so I popped the hood to check my fuses. And found out it was the fuel pump fuse. I had over a quarter tank of gas left and no warning as to any problem with my car. I check all my fluids on the regular and have oils changed when needed. When the fuel tank was pulled all the wires on the pump were melted. Lucky it dudnt catch fire, and the part to replace this is ridiculously expensive.

Tl- the contact owns a 2007 Ford Expedition. The contact stated that while parked, the vehicle was not able to start. The failure occurred constantly. An independent mechanic diagnosed the vehicle and found that wires connected to fuel pump had melted and needed to be replaced. The manufacturer was not notified of the failure. The approximate failure mileage was 90,000. Jo.

While driving in traffic, my wife's Expedition made a loud noise in the engine compartment. A few hundred feet later, it made the same noise, loosing power steering and power brakes, causing her to have to pull off to the side of the road with minimal control of the vehicle. The vehicle was towed to the nearest Ford dealership, who informed me that the fuel pump purge valve had stuck closed, causing the fuel pump to suck all of the air out of the gas tank and literally implode the gas tank and destroy the fuel pump itself. A search on the internet (youtube. Com in particular) shows that many Ford models 2009 and newer are having this same trouble with their newer style valve. I was told this was not covered under the emissions warranty, despite it being an emissions component, and that I would have to pay the $2600 to repair the vehicle, even though there was a catastrophic failure of a Ford factory part that caused the rest of the damage and left a moving vehicle with no power steering or brakes - not to mention that a damaged gas tank could have been a fatal fire hazard.

See all problems of the 2009 Ford Expedition 🔎.

Truck shut off at 60mph towing a camper because my fuel pump relay blew because of a defect in the fuse box!! almost killed us. . . . . . . . Not happy at all. I've spoken to many mechanics and been on many forums and this seems to be a wide spread and dangerous issue Ford should take care of. Spoke with the local Ford parts department and they are aware of the issue. This is not a cheap part by any means, but on top of that it almost killed my wife and family! please do something about this defect. I can send you pictures of the fuse box board so you can see the burns.

I purchased a 2007 Expedition a couple of years ago with 67000 miles. I've been having several issues with it but I figured it was just because it was a used vehicle. I maintain my car very well getting all of the service it needs done. On 4/12/15 I was in the car with my two daughters and it just stopped in the middle of the road without warning. This was an extremely dangerous situation and we all we very afraid. Luckily the car behind us was not too close and was able to prevent a very serious accident. I am being told that the problem is related to the fuel pump. I filed a complaint with Ford on 4/15/15. All I was given was an apology and told that there was nothing that they could do at this time. Little did I know that there would be a major recall just yesterday, 4/29, for the same issue with their newer vehicles. I also see an outstanding number of complaints about this with the same version of my 2007 vehicle. I guess that Ford is waiting for someone to die before they recall this issue. I am extremely upset about this and will not stop over turning options until Ford does something to fit my vehicle.

The truck just quits like running out of gas stall no steering now braking very unsafe it is because the fuel pump relay is built into the fuse junction box not serviceable and if you have a moon roof the drain runs down that side the water drips on fuse box shorts out the relay and off your truck goes they only did it 2 years and they obviously now about it and changed it and the new part different number.

When driving on I-10 west at 65 mph my Ford Expedition shut down for no apparent reason. I was in the far left lane and don't like to park in the interior lanes so I placed my hazards on and drifted to the far right lane. It was hard to do because when my vehicle went dead the pwr steering and brakes became hard to use. Once I got to a safe area, I tried to start my vehicle again. . . . . Without success. I contacted my insurance company for roadside assistance and they picked my vehicle up and towed it to my residence. The next day I started the vehicle and went to a doctors appt. On the way back from the appointment I was in the left turning lane and the vehicle died again. This time I had someone behind me that almost rear ended me. At this time I took the vehicle to the Ford dealership (shamaley Ford). They indicated that the fuel pump was defective. I retrieved my vehicle and replaced the fuel pump. When driving to ensure that my vehicle was operational it died again on me in the middle of a one lane street which nearly caused an accident. Someone helped me push my vehicle around the corner so that traffic could proceed. I waited about 10 minutes and tried to start me vehicle and it started. I hurried and placed it in my parking space. As I have read, this is a reoccurring issue with Ford Expeditions and luckily this hasn't caused a major accident or resulted in death. I did not state this but I connected my code reader and there was no indication of anything wrong. As stated previously, I took my car to the dealer and they misdiagnosed the problem. Could you address the issue?.

The contact owns a 2001 Ford Expedition. While driving approximately 55 mph, the engine stalled and the engine warning indicator illuminated. The vehicle failed to restart and was towed to an independent mechanic. The mechanic stated that the fuel pump needed to be replaced. The vehicle was repaired and the manufacturer was not notified. The VIN was unavailable. The failure mileage was 114,000.

See all problems of the 2001 Ford Expedition 🔎.

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!.

The engine would randomly shut off with no warning. Sometimes the engine would shut off while driving, other times would shut off at a stop light. The issue happened 10 times over a 3 day period. I was lucky to not crash as the engine died once while making a turn on a busy road. Once it died, so did the power steering and brakes - very scary. There were no engine codes that came up and no indication anything was wrong, the engine would simply shut off. While diagnosing the issue I did some internet research that indicated it could be the fuel pump relay issue. The fuel pump relay is a non-serviceable relay that is soldered to the main fuse box circuit board. I removed the fuse box and disassembled it revealing the fuel pump relay was getting hot and had melted the solder on the board. When the relay cooled, the solder made contact and the engine would start right up. When driving the solder would warm up and break contact. This would shut the fuel pump off and the engine would die. There are reports of this all over the internet. The only repair for this item was to replace the main circuit board as the relay cannot be replaced without soldering to the circuit board. Once the fuse box was replaced, the issue was resolved. I believe this could potentially be a huge problem and could lead to serious accidents. I have read this problem affects numerous years of the Ford Expedition.

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.

Fuel pump arced internaly inside the fuel tank connector shows signs of open spark.

Was driving down off ramp lost all power to the vehicle, no steering, no brakes. I had my 3 children in the vehicle with me and thankfully I was able to cost to the shoulder until help arrived. Extremely scary had it happen 2 minutes earlier would of been off the ramp and into oncoming traffic! this is unacceptable!! my mechanic says it's the fuel pump, and just the part is 500 dollars?!? this could of ended very badly and I have had nothing but issues with this piece of junk. The paint is peeling off, looks like no primer or sealer was used it literally is flaking off on the hood and rear gate right where you would put your hands to open it. In the manual in very small print it says the oil from your fingers may cause paint to corrode, are you kidding me??? your not supposed to open your hood or tailgate??? ridiculous!! this vehicle in my opinion is a lemon!!.

See all problems of the 2006 Ford Expedition 🔎.

Was driving my SUV and was coming close to my turn off let off the gas and my vehicle cut off had to steer to side of the road. Had fuel pump replaced was driving the next day after pump was replaced stopped still and the vehicle started shaking and cut off. It started up about ten minutes later. The next time was riding down the rode going 55 and my SUV just shut down I veered it to the side of the road was able to start it tried to head home vehicle shut down a good 5 miles and was able to start again after waiting this happened again 4 more times in the same nite before my vehicle didn't start anymore that was March 31,2014 it left me stranded on the side of the road with my three children. Eleven days later my vehicle is still not starting and diagnostic test is not showing anything wrong!.

I was driving home from work and my Ford Expedition started hesitating. I was driving on winding west virginia road at the time. Vehicle stalled out after hesitations. I was able to restart and bring the vehicle back to speed. It hesitated several more times. In town when starting from a stop it stalled out twice more. Stalling occurred as I pressed on the gas pedal. I brought it in to the dealer. They changed the ignition coils. As I pulled out of the dealer it stalled out again. I was in the middle of the intersection when this occurred and was very lucky that this did not cause an accident. I brought it back to the dealer. They had to change out the fuel pump. The side the electrical wires on the pump had melted and were making intermittent contact causing the hesitation and stalling. This could have very easily caused an accident.