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truck broke down today


dashhho

Well-Known Member
Joined
Sep 12, 2020
Messages
184
City
Canada
Vehicle Year
2005
Engine
4.0 V6
Transmission
Automatic
Got about 1km down the road and I noticed I lost engine power. I looked at the tach and it was at 0rpm so I took my foot off the gas and it moved up to about 500rpm for a few seconds and then the engine shut off completely. I coasted to the side of the road. Towed home.

Engine cranks over but wont start. No codes came up when I scanned it.

I am thinking it is the fuel pump? Has 260k kms on the truck.

Any ideas for troubleshooting the fuel pump system? Or other opinions on things to check that it might be??
 
Just when you turn the key to the ON position and not start, you can/should hear the fuel pump kick on for about 3-5 seconds. If not, that's a good indication and start point. Obvioous things like fuse and relays of course.
 
Rumblecloud's suggestion is a good one to go with. Verify it is the pump not only by sound (sometimes it can be hard to hear if there is a lot of background noise) but by spraying starting fluid or brake cleaner into the intake. If it starts or sputters, you have spark and it's a fuel supply problem.

When checking the fuse, look at the pins as well as the center section. I had a fuse that otherwise looked perfectly fine but killed my pump. There was some brown residue on the pins. After a day of troubleshooting, I replaced the fuse and the truck started right up.

If the fuse isn't the problem, check the inertia switch behind the passenger side kick panel. Those have been known to trip for no reason from time to time.

If that checks good, try a rubber mallet on the bottom of the tank where there is a circular impression in the plastic. Sometimes jarring the pump will getting spinning. If that works, it is a temporary fix at best and the pump needs replaced.

If it doesn't, check power at the pump connector to verify there isn't a wire problem. The easiest way to access the pump is to remove the bed bolts and prop up the front of the bed securly. Dropping the tank gives only minimal access at best since you can't drop it very much with out removing the tranmission support cross member and proping up the transmission. Even then access isn't great and depending on how much fuel is in the tank, dropping and lifting the tank could be a real chore.

Be prepared to have issues with the bed bolts. Get some replacements from either a dealership, a Ford website, or a suitible replacement with the right diameter and thread pitch, by removing one for comparison, from a hardware store. I believe the bed bolts use a T55 torxs bit. My truck had two different lengths, depending on where they were in the bed. You might have to cut some or they will snap in the removal process. But pulling the bed is still going to be the better option than dropping the tank.
 
I agree with both @rumblecloud and @sgtsandman .

I will add that sometimes the clips/connector where the fuel pump relay plugs in get to a point were they are separated somewhat making it so the relay doesn't get good contact.

As for lifting the bed up. I use a fence post to hold the bed up.
And ratchet straps hooked to my door latch pins on my door jams and over to the post holes ( ladder rack holes ) at the front of my bed to hold the bed up against the fence post.
IMG_20250311_120758338.jpg
Like you see in the picture above.
 
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/\ holy cow, your truck looks ready for a low rider competition with the bed that high.

i undo the bolts and just lift the driver side with a 2 foot piece of 2x4, so its tilted a little bit.
 
I'm a short ugly fat guy that wears glasses.
So I move the bed out of the way, so my fat butt can get to whatever I'm working on .
And at the same time I do my best to be able to see everything I'm working on as well.
 
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It sputtered with some brake cleaner shot in the intake. So seems like fuel pump.

Is there a chance the relay is bad?
 
It sputtered with some brake cleaner shot in the intake. So seems like fuel pump.

Is there a chance the relay is bad?
Maybe. Test it by swapping a similar relay into the same position. Don't go buying parts until you know what is wrong unless you have to. Throwing parts at a problem without finding out what the cause is just makes you have less money and still having the same problem.
 
It's not really very had to test a relay.
You can find All kinds of videos on YouTube about it.
 
Tried swapping a relay and still no start.

I tested the pins where the relay goes in with a test light. power is getting to the relay (largest pin). And when I turn the key on power is getting to the relay in the other pin. So I think power is getting to the pump.

Any other ideas? I am thinking it's time to lift the bed to test the pump.
 
So you now know which two pins are the powers for the relay.
You've got two more pins left 1s the ground.
The other one goes to the fuel pump.

Run a jumper wire from 1 of your power pins
To the pen that operates the pump.
Count 1 Mississippi 2 Mississippi and then unplug it.
Then see if your truck starts.
 
Ah I see what you mean. Tried that and nothing.

Is it possible the ground is the issue?
 
I tested the ground at the relay and am not getting any reading. Is it possible the pump caused this?
 
So I think power is getting to the pump.

The next place I'd check is for power in, AND power out of the inertia switch, passenger floorboard.

And, I'm assuming that '05s are set up like the earlier ones.
 
Is the black plate on this connector supposed to be able to come off?

It's the inertia switch connector
 

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