2004 - 2008 F-150
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2004/2008 fuel pump ground problems

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Old Aug 24, 2019 | 09:10 PM
  #1  
moemoe's Avatar
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2004/2008 fuel pump ground problems

Hello everyone I would just like to pass on some information about the 2004 to 2008 trucks.
I recently had a problem with my 06 5.4 the truck would start and barely run then stall no codes,five or ten minutes later it would start and run fine and stay running fine until you shut it off.
Then when restarting again it could be fine or misfiring and stall no codes,I finally got it to set a code when I was checking live data on scanner,it was the code for the fuel rail pressure sensor.
The live data for fuel pressure at idle was 8 psi and I did not want to buy any parts I didn’t need so I checked all the obvious things first fuses ,wires,banged on tank,etc no luck.
I decided to change the fuel rail sensor and it ran good on start up first time but not second then the next day the motor would not start at all (please bear with me) ,ok so it could be the rear fuel module.nope
I pulled it out and it looked great but who knows ,we bypassed it but truck would not run so at this point we thought it had to be the pump.
We pulled out tank and tested wires to pump and they had good ground and power,ok it has to be the pump ,are we’re sure it’s $500 ?spent about five hours checking forums no answers ok let’s get the pump .
Installed the pump and went to start but it wouldn’t run ,checked old pump on bench it seemed to work fine but you never know.We hadn’t installed the tank so we pulled in old pump which didn’t work.
we checked the wires at pump and there was no ground so we went over everything again this time when following the main wiring harnesses down the frame we notice a cover on the frame under drivers door.
My son removed it and found 2 plugs a small and a larger one ,he opened the plug and it was full of green **** ,I cut this plug off and soldered and heat shrunk every wire.
The truck runs great now cost me a few bucks but it has 240000 Km, it was probably due for a fuel pump anyway,I ‘m guessing 2004/2008 only have these wire plugs under drivers door.
I live in Canada lots of ice and snow and salt ,I wash my truck once a week and the body is mint so who knows.
If your having weird problems check this plug first and pass this info on. Sorry for the writing Cheers
 
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Old Aug 24, 2019 | 09:25 PM
  #2  
ManualF150's Avatar
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Joined: Jan 2007
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From: Vernon, NY
Good to know.

Also the FPDM likes to crack and mutilate itself from corrosion. This also causes weird things like this.
 
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