I just had a similar problem when I went to get gas at speedway this morning. Thanks for the video. Interestingly after doing everything it still wouldn't start. I thought it was the pump but it's given no sign of going out, and then it occurred to me that the car wouldn't start if it's not in park so I put the key into the on position shifted in and out of park to neutral to drive then back to park and presto started right up. It's happened before but it was years ago. I've had my 07 ford expedition for a long time and currently at 300k miles I've traveled all over the United States and its still a beast. Thanks again for all you do here it's gotten me through many situations You should consider putting a video collection together on DVD and sell it. That's the quality you put into these videos I'd buy it 😄

Had a similar problem with my 2002 Explorer. Turned out a small rodent had gotten in the fuse box and chewed through the PCM ground wire to the fuel pump relay and chewed a bunch of insulation off adjacent wires as well. Absolutely drove me crazy. So the moral of the story is do a good visual check of the condition of the wiring as well as verifying circuit integrity and function.

Dude, you're a rock star! I feel relief when I look up a vehicle problem on KZfaq and find a video with your name on it.

Hi just happen to see this video. I purchased a 2004 Eddie Bauer with the 4.6L with 170k miles. Purchased from the auction and it started and drove 30 feet to clear a lane. The vehicle was a repo so it running condition was noted as run and drive. However after i saw the check engine code, I scanned it to see a misfire cylinder 3 only everything else was great. I shut it off, packed up my gear and turn the key and crank no start???? Took the vehicle to a shop and the tech diagnosed multiple codes for fuel pump, said fuel pump reset was not triggered and stated relays even the R303 was working properly his diagnoses... he also stated a theft deterrent code as if the SUV was not recognizing the key. I informed him of the many videos of the R303 to include yours; the BEST of them ALL, claiming the R303 as a relay as culprit. I asked the tech did he verify the R303, he says vehicle runs as long as you're pumping fuel in it and R303 showed good on his test. I feel that through your full diagnoses seen today, My Expedition with 170K is a victim of this relay R303 and the tech is making an attempt to take me for a financial ride as he want to replace the fuel pump and continue to charge to troubleshoot is there are no positive results. I am a disabled veteran former mechanic that has to now send my work out but I will not be a money pit for someone's financial gain! Any advice is welcomed... :)

Dude! You rock! My sister and I both have '03 Expeditions, and within a week or two of each other they both started having this problem Mine was worse. Died completely, and when I connected a fuel pressure gauge to the fuel rail, no fuel pressure. I assumed it was the fuel pump, and was going to replace it. My sister took hers to the dealer. Since hers was intermittent, they told her at first they couldn't reproduce. Then the next day, they told her it was the fuel pump. After watching your video, I went and tested mine, and bypass the relay like you did, and lo-and-behold, she started right up and ran fine! Amazing. Now to buy a replacement fuse panel. Thanks again! Keep doing what you do!

I was getting ready to pull the fuse box out of my wife's Navigator, to see it the fuel pump relay had burned up like so many do. Your video will help me test that relay before going to all of the work of pulling the fuse box and disassembling it. Thanks. I hope to locate the wire that powers that relay's coil (#303), then tap into it and mount an external relay and socket without having to remove and disassemble the fuse box. This way I can replace the relay easily if it ever burns out again. I would suggest to anyone repairing or replacing this fuse box board, that they replace their fuel filter at the same time.

You are very articulate one of the most informative videos I have seen excellent camera work for a one-man band you do just fine thanks

Thank you, my 2004 Expedition was randomly stalling and last night would not restart. I ran through this test and jumped the fuel pump just like you did in this video and presto, the car started. I ordered a new relay to solder onto the board, unfortunaly no one local will sell the relay and will have to drive with the jumped wire for couple days but at least I wont spend 500 on a whole new board.

I wish you were in my area. Id ask you to check mine and pay your fee. 😂

Gracias joven por compartir tu talento de reparación

Brian was very knowledgeable as you all know. I wanted to thank you once again for the diagnosis on my truck. I appreciate you coming to my location.

Two questions. Can a faulty relay cause the engine to vibrate at times as if the ignition coils are misfiring? Does the 2004 Ford expedition also have a fuel module that can cause the same issue?

Nice job. Everything was well captured and expertly described. Thanks!

I've always hated the way Ford uses internal non-replaceable relays. I've done a couple injector cleanings with the OTC tool that flushes via the fuel rail, and I've ended up disconnecting the IFS switch to disable the fuel pump as pulling the fuel pump fuse also disables the injectors. Wish I'd have known about the 4-pin connector and that there's nothing else critical on it. I'll do that in the future. Great video!

a simple quick test every car or truck usaully has a large fuse next to it in the box under the hood,just try using the fuse relay next to it swat it for temp fix wala starts if not back to drawing board.i always carry circuit breaker,male to male jumper wire,cube type relay in glove compartment.

Just wondering if it would help to have the fuel pump relay power an external one that could better handle the load.

Thank you for this diagnostic walkthrough! You saved me from dropping a fuel tank to go after the pump!

Yep same issue I had on my 04 5.4 2valve. The relay was like $5 for two off of ebay. Resoldered it myself. Dealership talking about $600 for repairs... lol shitting me 🤣 😂 😆 😅

I have lost ground to my ignition coil I do have constant positive but no ground .do I have a fuse or relay I can check or could be the pcu?

2003 E450 doing same thing, but I'm uncertain if it has non-servicable relays inside fuse box ?? Will apply 12v to pump as done here today.

what ground / power can you use as reference point if your leads aren't long enough to reach the relays from your battery?

Can you run a straight hot wire from the battery to check the green/yellow wire to see if it will start

In order to turn on the fuel pump by connecting 12 volts to the wiring harness like in the video, do I need to also supply a ground to the harness as well? Thanks for the help.

I love your straight forward quick but detailed and complete diag. methods of diag. very impressed as I a a tech as well. may thanks

Thanks man. You are such a good person

I just repowered my 2003 Ford Expedition. It started up immediate but it won't start the 2nd time. Amy thoughts thanks

I got same problem here on 2003 navigator. My issues here is when i try to star up a winning noise came from the fuse box and no crank nothing only lights on the dash. But if i disconnect the plug for fuel pump cranks but don star. I put 12 volts like you explain strait to the pump but nothing i check voltage from the pin and i got 12 volts i replace the fuel pump and still the same.... Please help me

Nice video. I assume to fix your truck you replaced the central junction box / fuse module? Seeing as the fuel pump relay is soldered in place, can a fellow save some bucks by pulling the relay and soldering a donor in place, OR, could you solder pigtails for a standard 12V relay onto the board and have the relay situated external from the central junction box? I'm assuming the central junction box might be pricey?

Great confirmation of fuel pump relay function. I did check my 2003 Expedition 5.4 2V and the relay found to be good. But I seem to found out I have no spark and fuel injectors are not firing and no trouble codes, could that be a PCM/ECU failure?

Very intelligent man, Thank You!!!

I understand about half of what you said

Could you help with my problem on Ford Expedition 2000 model? My problem is the engine crank but no start. I noticed that there's no fuel supply at fuel rail. I also found that the fuel pump relay has no "NEGATIVE" signal, but the ignition supply and B+ is present. Even I jump a wire from relay coil +supply goin to fuel pump enertia switch ..the positive there coming on and supply the pump but still it doesn't start I don't have a diagram for this model. The main problem is NO NEGATIVE signal on fuel pump relay. I check the voltage at CKP and measure it's resistance I got a reading og 1.5 volts on each wire with my negative probe is on ground. And got 360 OHMs for the CKP sensor. I appreciate any hint you could give on my problem.

Dude your video is awesome. I wired in my own relay to bypass it.

It would help if you told us what part name, or part number was required to replace that fuse block. Also would be helpful to know where to buy it at a good price & a link would be great.

Freakin love this guys show!

Thank you for taking the time to make this video and the in-depth explanation of the diagnostic procedure. Much appreciated!

to whom it may concern...I had a crank, no start on a 2003 ford taurus 3.0. I had fuel and spark. Tooka while to figure it out, but the sumgun was FLOODED! I didnt think fuel injection could flood, but apparently it does. here is the fix..FLOOR the gas pedal prior to starting it. Apparently this signals the computer to shut off the fuel pump until it starts. I wonder if it is just too much pressure on the fuel rail or what, but it started up and sputtered for a bit. Then smoothed out. Just an oddball situtuation that may help someone out.

Item worked just perfect....saved over $600 by installing myself vs dealer($1000.00)

i suspect a faulty fuel pump for mine. I did a battery bypass like in your video and I still don’t hear the pump prime. When I do KOEO the load runs for about 2 seconds and then drops to 6.6v. When I crank, the load(halogen bulb) turns on and the volts jump up to 12.3. The engine starts running if I use starter fluid so I know everything else is OK

The fuse box from the expedition2004 and 2005 is the same box?

Your a very good tech.thank you for the video's you make.

Hey Brian, I know u mentioned that po1233 and or po232 codes may be displayed but when u first diagnose the vehicle was there any actual stored dtc(s).Because I have 2003 Ford Expedition with no dtc(s) present but with simulated intermittent symptoms in which I'm suspecting fuel issue as well.

You have the best videos on KZfaq 👍🏻

thank you boss one more question, if I buy one from an 05 expedition are they interchangeable?

Good Video thank you sir 🔧🚗🇺🇸👊💪I have one of these first one I've seen there's a place in Florida who sells a refurbished fuse box and you send them your old one they say life time guarantee I ordered it I'm replacing the fuel cut off switch to its got some high resistance over 10k ohms when it put power to the plug at the fuse box car still won't run won't go the the cut of switch only have 2.7 volts out of the fuse box I can put 12volts to the exit wire to the pump out of the cut off switch and it will run

hi.. new here... working on my neighbors truck which 4 shops have not been able to fix. the truck died on the highway. restarted and went a few more miles before dying again and now wont restart no engine codes except a pending code of P0102 which i think is not related. cranks.. no start. 06 f150 4.6 4x4 the fuel pump does not turn on under any circumstances....UNLESS ...when the fuel line to the engine is removed, either at the tank or at the fuel filter, the fuel pump will engage and has good pressure at the outlet when i turn key to start????. he already replaced the fuel filter and camshaft position sensor. i back probed the green fuel pump wire in the passenger footwell and did not see voltage when key set to start. i ran 12v from battery to that green fuel pump wire and pump did not run. any idea where to go friom here? is it likely that soldered R303 relay is ba

Thank you. Exactly was happened, saved me a bunch of money by just replacing a bunch of stuff that i didn't need to

My 2003 expedition will cut off when driving after stumbling. The last time I got it restarted and limped home. Would not start after I got it home. 3 days later and a dead battery (door ajar drain I think) I put my booster pack on it and it started right away and ran for 30+ minutes. Is this the relay? Please help!

very informative video. thankyou

How do change the fuel pump relay? Can you desolder it and replace it with a new one?

Question. I have an 03 Expedition. Did the same thing. Replaced the relay, even bought a new fuel pump since the SUV is 16 years old and I don’t know the history. After 2 weeks running great it started back doing the same thing....no start. Alternator and battery, fuse link are all good. Power to the fuse box to fuel pump is great, no shorts. The relay is not supplying power to the fuel pump. Question is, what would make a relay go bad? We are now going to replace it again for a second time. Just wondering what else we are missing?

Over my head, damn it.

Great vid but you never mentioned the fuel pump realay R303 wich is a big problem on this cars and its not removable its behind the mother board.

I'm in Indiana and I sure could use your services. #StaySafe & #StayBlessed

Would a 2008 E 350 van be somewhat the same as this?

not sure if its the same thing, but might has a hard time starting, would have to crank it twice or three times, and it sputters, feel rough for a few seconds, and the smooths out, idles fine and drives fine, could it be something similar?

Do you ever use a t-pin to backprobe connectors? The meter probe tip is harder to get to the back of the connector pin.

Is the direct lead from the positive side of the battery simply one direct cable line to the yel/green socket? or does it require a ground somewhere? I am confused!

Great video always informative, but how do I perform this same diagnosis on my SVT F150 Lightning with the 5.4L V8 2 valve Supercharged?.

I have a 2004 model parked it in a parking lot then came out of the store and no start, I replaced the relay in 2016 and checked it and the fuse and both are good. I ran the hot lead from the battery to the green wire for the pump and it does not come on. How can I be sure it is the pump and not the inertia switch? I have pressed the button and it does not click it only springs back up.

Great videos! Hands down the best Ford mechanic around! I would like to add one item to check ,to the list. Mine ran fine to work, at the end of the day it wouldn't start. After checking a few things I saw in the video, found it needed a FPCM, unplugged it to change and discovered that the ground wire pigtail for the plug had corroded completely off the frame. One 10 cent ring connector and it was back in business!!! Just a heads up!

My 2004 shutdown twice yesterday. No crank, no lights, no shift, and not signal. I wiggled the cable that runs to the fuse box and the lights came on and the truck started. I took the rubber cover off to the terminal and noticed it was melted a little bit. The bolt was tight not loose.

Does the power coming directly from the battery to the yellow/green wire test-- prove that the fuel pump is defective if the car will not start?

I went to U.T.I in houston 2001. love those snap on meters.

Hey ford tech on these fuel pump relays (internal/circuit board) one guy said he was going to try to wire to an external relay to never have to buy another 500.00 fuse box. Will that work ?

Have to let my 04 v10 prime for like 5-6 dings or it won't start first go, sometimes a couple of tries... Was wondering if pump, relay, or fuel driver if it has one

I need your knowledge pleeeease. I was working on my truck. I had the positive battery cable off. When I was finished I noticed the cable was touching the frame before reinstalling it. Truck won't start now but turns over. 5.4l 2004 f150. TY

what would happen if you get nothing from hooking the fuel pump up directly and 6.6 voltage at the fuse box side of green/yellow wire plug-in?

Will the light on dash flash quick

Hey i got question i got 2006 ford focus no crank no start..car was running fine and quit..blew #9 20a fuse changed it..got power all relays and starter but have dashes on odometer and no crank no start..any suggestions?

Just replaced my fuse box on 2004 f250 thanks for a very accurate video very helpful what were they thinking making this relay non serviceable $400.00 for replacement verses $10,00 for a plug in relay

awesome video! did one not to long ago. my repair was splicing in a bigger relay with an extra fuse.

On my 04 expedition the code p0231 it says secondary circuit low what does that mean?

After you bypass the relay if the truck doesn’t start, does that mean that the pump is also bad?

Hey Brian, sons 03 expedition with no fuel pressure. Ran wire from battery to green/yellow wire and fuel sender doesn't prime? Looking for some wisdom if possible. Great videos, I wish I had your knowledge.

Hello, seen you instructional video and saw the electrical diagram for the car. Can you send me a link to see it or make a video out of it.

Great job with explaining everything, just one quick question , when probing the pin on the pdb are you only supposed to have battery voltage for the initial 2 seconds or constant? Because I get battery voltage(12v) and then it drops to 6.6v thanks!

Hi I have ford expedition 2006,i have a problem with stating up the engine, but it does not come regularly some time the car starts good but other time not start up (dead). when it is not start up I try to bring THE GEAR on N and little push and bring it to P again then the Engine start. could you please advise what I should check or what is the expected problem. Thanks and appreciation in advance.

I have a f150 from 2004, I try to start it, it stays starting but I put gasoline directly into the trotel and it turned out that it could be. some relay or fuse. she had turned me on well and for now she turned off

Great vides - thanks have an '08 expedition. Car runs fine with and there are no intermittent driving problems. Checked fuel pressure on Schrader valve. I believe i have a bad valve adapter since I have no fuel pressure reading. What is the correct adapter for the valve and do you know if it is available at Amazon? Thanks.

EDIT 4-07-19 Since I too am a one man show with no IDS tool/software to assist I first tested the fuse 20 fuse - 12.7VDC - Good. I back probed the DG/Y wire and with the ignition ON have 12.7VDC. With no easy way to load test, I start the truck. Is it normal for the voltage to drop to 10.5-11.5VDC during cranking? It returns to normal afterwards. I'm starting to lean towards a fuel pump issue. I suppose I will bypass the FPDM and wire in a spare battery to the pump and try and start. If that doesn't do it then I'm replacing the fuel pump..right? (No other error codes and I have a new FPDM and FRPS. Short of a wiring issue or ECM not sure what else it can be, Are the F150 for the 2004-2008 the same as this? I have this exact symptom and have a new FRPS and FPDM and still have a no start situation with what I believe is a 2 second pump prime when the switch goes to the ON position. No codes either. ??

Very thorough analysis and clear video. I have a 2004 Eddie Bauer model. Any idea on where to get the fuse box in South Florida?

I had this issue on my 2003 Expedition. My car would randomly stall and it got progressively worse. It was the fuel pump fuse block on the back side of the the fuse box. I was going to replace the whole fuse box but then found a repair shop on E bay that specializes in this exact repair. I mailed my fuse box to the company and it was repaired and returned within a week. Total cost of repair under $75.

Hi there, if i bypass the internal relay with an external, would my check engine light stay on all the time?

I have 1999 ford expedition. P0171 & P0174 codes. It runs, but only 15 psi at fuel rail. 6.5V at inertia switch plug with key on, goes up to 12v when cranking. I swapped relays. Same result. Powered pump directly from 12v battery. It still shows only 15 psi (tried 2 different gauges, fuel filter not plugged). You think it could be the power box connectors? Should it be full 12 with key on or is the 6.5 right for the 2 sec pump run? Or do I have 2 problems.

Excellent , and very well articulated. Does the vehicle in the video have the 5.4 L ?

My fuel gauge is bouncing all over the place. I filled up my tank, started my car gauge read empty. Car still starts up drives, watched one of your other videos you said pour some techron plus in the to help clean fuel pump and sensors. Tried that and fuel gauge jumped to full for a day then started bouncing all over the place again I used two bottles of the techron. I have no codes popping so its hard to pinpoint whats wrong. I replaced the fuel pump driver module still no results. Do you have any suggestions. Car still runs and starts up everyday. This is been going on for like 2 weeks. Just stuck.

Would this be similar on 2004 f250 sd with 5.4? I'm having same issue but I know fuse box under dash not in kick panel

May you tell me the specification of the T50 Torx bit you used to remove the bit from the taurus tensioner pulley? Is it 3/8" drive or 1/2" drive Thank you

I tried jumping the wire straight to battery but still not hearing fuel pump , and it won't start ,just put another new pump in . What do I check now ?

2011 f150 headlights and tail lights randomly turn on then off. Same with center console and radio. Any suggestions on what it could be?

Is this the same for 2007 ford expedition xlt el eddie bauer? i cant seem to find fdpm thanks

@fordtechmakeuloco. Another question. Why cant you just wire in an external relay to bypass the BCM? BCM is $510 and programming is $220 which is $730 total if you can wire around the BCM to drive it to Ford in order to avoid a tow. This is a really steep price compared to the older relay in the fuse box which was a $5 dollar relay and 5 minutes of labor.

Fuel Pump Kill Switch? Dear sir, where can I splice in a anti theft kill switch?, what wire do I cut and put a kill switch? Thank you

Great video Brian. By the way how reliable and what should i look out for on an 07 fusion v6 awd

We replaced our fuse box and now the alternator is overcharging the battery? What could this be? Could this have been the problem all along? Please help! I been stranded at home for 2 months.

how about no crank at all? is it usually just the starter solenoid or starter itself? 04-Expy-5.4L 175K miles, fuses and relays okay.??

I wish you were in Texas. I have a 1997 f150 5.4l with a crank no start issue. I thought it was the fuel pump so I changed it and had to reset the inertia switch and it ran for a month then died on me. Back to crank no start. Replaced the ecm and it ran for a day. Back to crank no start. Can you help me at all?

I put new alternator I replace fuse box and fuse link truck runs but I have battery ligh on and alternator don't charge I have 12.6 all time what's gonna be??? Thanks for u time

I have an 04 Navigator with fuse 102 blowing when I turn the key. I have replaced the starter and ignition switch but still no luck it did die on my while driving... please help