Fuel Pump problems of the 1997 Ford Taurus

1997 Ford Taurus wagon. Over the past two months, the vehicle stopped dead in traffic 5 times at various speeds with no advance warning. It would not restart. The fuse to the fuel pump repeatedly blew, but no other problems were evident each time the car was towed to the garage. The engine would run roughly, stall, and surge, but the problem was intermittent, and gradually became worse. The mechanic suspected a problem with the fuel system. An investigation revealed that a wire to the fuel pump inside the fuel tank had its insulation worn off down to the bare wire, and had shorted out. Other wires also show signs of wear, but are not yet worn through. I have digital pictures of the wires. The wires were damaged due to the way the fuel pump was assembled within the gas tank. This is an obvious manufacturing defect and is not limited to only our car. Ford has issued 3 TSB's relating to this problem (98251, 5226, and 12189) and I have also found several related complaints in the NHTSA database (odi id 549996, 707889, 713208, 807546, 838030, 853283, 879245, 10018293, and 8012733). I am concerned that this problem could not only cause complete vehicle failure (loss of power steering and brakes) at any speed, but also that the possibility of a spark inside the gas tank is not out of the question. This wiring problem should be investigated as a possible cause for any Ford Taurus fires, or accidents involving loss of power. We are convinced that this is a manufacturing defect and that the possibility of more related accidents increases as current vehicles age. Ford evidently is aware of this problem, or they would not have revised the wiring harness and given special installation instructions to their technicians.

While consumer was driving the vehicle, it stalled in the middle of traffic. Consumer had taken vehicle to the mechanic, and they found that the fuel pumps positive wire was cut on a sharp edge inside of fuel tank, which left the wire exposed to the fuel tank, and caused it to short circuit. Consumer adds that Ford is aware of the defect, and now places a protective cover on the wires.

While driving 55 mph vehicle began to lose power. Shortly afterwards, vehicle completely shutdown. Problem occurred due to the fuel pump. Please give any further details.

While driving about 55 mph vehicle suddenly stalled without a prior warning, and had to be towed to service shop where they find out that a fuse was blown in fuel pump.

Vehicle would hesitate & wouldn't stay running. Wires for fuel pump had rubbed against flex hose, causing it to expose the wires & short out. Dealer cold do nothing because no recall. Also the cv joints failed and the transmission pan cracked. The brakes vibrated causing the steering to vibrate terrebly. The vehicle, the consumer says, must be defective.

Vehicle initially lost power on incline and regained on decline, until total loss of power after 2-5 mph. Occurred on four occasions, on highway trips. Dealer initially reprogrammed computer then replaced fuel pump relay. After fourth occasion, replaced fuel pump. Also, transmission is sluggish, difficulty gaining speed on initial acceleration. Then suddenly surges/hesistates and moves erratically into gear. Vehicle hesitates and acts as if it stalls out.

Engine stalled in traffic, nearly caused crash, owner told by dealer, to never allow fuel to get below fourth tank, fuel pump naturelizer stopped operating. Dealer is replacing naturelizer .

While driving fuel pump malfunctioned, causing vehicle to stop. Consumer had vehicle serviced. Mechanic stated that it was fuel pump, and has to be replaced. Please provide further details if needed.