Well, that was interesting.
 

I drove my 02 F150 with 5.4L engine to Sams club and picked up some food. After loading the food, the truck wouldn't start. The starter spun the engine fast like always but it wouldn't hit a lick. After trying a few times over 10 or 20 minutes, I called a tow truck and had it towed home. After unloading the food, I hooked up my fuel pressure gauge and hit start. The truck started immediately and is running well???????? Fuel pressure is 30 psig. Any ideas fellows? Oh, it has 148,000 miles on it and probably has the original fuel pump. I bought it in 2009 when it had 69k miles on it.

30 psig is at the low end of specs (28-40). When was the last time you changed the fuel filter?

Roadie, I had a similar issue with my '02. It was the PCM power relay. My mechanic replaced it and haven't had an issue since.
Everyone, including me and the mechanic thought it was the fuel pump, until he ran a check on everything and discovered a random short in the PCM power relay.

It may be due again. I've changed it a couple times at least since I bought it about 80k miles ago. When i first bought the fuel pressure gauge a year or more ago, I checked it and it was 30 psig then too.

I drove it on an errand again today and it started both times. I put my fuel pressure gauge and step ladder in the truck so if it fails to start again, I'll check the pressure when it isn't running. I didn't think to crawl under the truck and kick the fuel tank when the truck didn't start. I may get the pump replaced anyway. I'd hate to have to call a tow truck when I'm on the beach. I suspect they charge megabucks.

More likely, it was an "intermittent open". A "short" in the relay wouldn't cause your symptom. Usually, if the PCM relay fails, you'll see only dashes in the digital odometer and you'll have a PATS light triggered.

Problem could easily be the fuel pump. My 95 Mustang did that to me a couple of years ago. Started right up when it got rolled off the flatbed in front of my garage. It got a new fuel pump anyway since we couldn't hear it cycle during the priming cycle when it failed. Lsten closely next time it fails, if it does, to see if the pump runs or not.

Thanks

Thanks

Your symptom and some of the replies remind me of the problem I had with my old 1991 Honda Accord. Once in a while, it would not start when warm. The starter would turn over just fine, but the engine would not fire. I could get it to start after waiting a bit though.

The problem was a "main relay" behind the instrument panel. An internet search told me this was a common problem with this car. I took it out and discovered some of the solder joints on the circuit board in it were cracked. I repaired these and never had a bit of trouble starting again. My Granddaughter now has the car and she is having no trouble with it either.

I'd be willing to bet your problem is something similar. Possibly in the PCM relay or in the Fuel Pump Driver Module?

Let us know what you find out.

- Jack

2004 (NBS) was the first year for the FPDM configuration. An 02 won't have one.

Thanks, I wondered about that, but was too lazy to check.

The intermittent nature of the problem still sounds like it's electrical in origin to me. Much as you described in your post.

- Jack

I had a similar problem with an 86 Chevy Cavalier a couple of times. I changed out the ignition module and it never happened again. I also had a similar problem with an 89 Ford Escort GT that I bought for my son. I'm not positive what fixed it. I did reset the inertia switch several times during the process of trying to find the problem and it never happened again and lots of miles were put in it afterwards.

If it happens again with my truck I have my fuel pressure gauge with me so i can check the fuel pressure and if it doesn't have pressure I'll rap on the tank to see what happens. If it has pressure then I will know to look elsewhere. I appreciate all the suggestions and knowledge provided.

Around 102k on the clock and my 2003 4.6 had extended cranking and no fuel pump last time I tried to start it. So I figured she was telling me it was time to pull the engine and get digging into the Coyote swap :lol:

I did lots of rebuilding, modifying, and swapping engines when I was a young energetic pup. But now, I'm a few days from 74 and the energy and the interest is just not there any more. I still do most of my repairs but these newer vehicles are just too much of a pita to work on. The last time I pulled the engine from my 65 Chevelle, it took one hour from turning off the engine to having the engine/transmission swinging from the hoist. Now it takes many hours to change the spark plugs in my truck.

I hear ya on the energy thing, and the over-complication of vehicles

All our Sam's Club stores shuttered their windows and booked town... ;) I didn't think they had anymore left..

Good luck on the fuel situation Roadie..

Mitch