2002 Sport Trac intermittent cranks but will not start

[JimInRadfordVA]

problem came out of nowhere a few months ago. Truck left us stuck in a parking lot. Had it towed and when they went to take it off the flatbed it started.

While at the shop I asked them to check it all over and advise. They changed the plugs and serviced the fuel system (cleaned injectors, changed filter, cleaned throttle plate, etc.) replaced the fuel pump relay at my request and the truck ran fine. A few weeks later, my son is driving it and it stalls as he's driving down the road. He waits a little while, goes back and it starts and runs just fine.

A month later, my daughter is using it. She parked it and when she came back it would crank but not start. Waited an hour or so and it ran fine.

Last week I went to use it and had the same thing happen.

There are no stored codes in the ECU. I replaced the rollover switch - still no start.

Based on how it's acting, it sounds like a "no fuel" issue. What should I do next before I throw a fuel pump at it?

 

[swshawaii]

Fuel pressure tested?

Key On Engine Off (KOEO) 60-65 PSI

Engine Running (KOER) 60-65 PSI

http://www.explorerforum.com/forums/showthread.php?t=170334

 

[rangerxr7]

crank / no start

For crank / no start ck grounds at battery, also seen issues with the fuel pump relay not staying on causing random stalling . for no crank ck the grounds at the starter.

Hope this helps

 

[JimInRadfordVA]

Fuel pressure tested?


http://www.explorerforum.com/forums/showthread.php?t=170334

Zero fuel pressure at all times.

Reading through the forums, I've seen several instances of similar symptoms caused by a corroded connector. Aside from the connector at the pump, where might I find other connectors in the circuit?

 

[HELMUT RONER]

I bought my 2002 in late March 2015 with 163K on it. In the first couple of weeks of owning it I read about a lot of pressure loss/drain back problems with the factory fuel pump. The fuel pressure regulator is located on the fuel pump assembly inside the tank. Roughly 30 seconds after shutting the motor off the fuel pressure bleeds down.. You have to turn the ignition key to the ON position, wait 3 seconds, repeat 3 to 4 times, then start the engine. Cycling the ignition key primes (pressurizes) the fuel system. From what I've read many have solved this by simply replacing their fuel pump.

Note: 2002 is a year where there was a design/part number change. You need to know the build date (located on driver door decal) before you select the fuel pump part number you will need. There will be descriptions stating built to 03/04/2002 and others stating built from (or after) 03/04/2002.

 

[rangerxr7]

connector

Don't know about explorers but on rangers they have a body to frame connector under / behind the drivers seat that corrodes that kills the fuel pump

 

[JimInRadfordVA]

Well, Saturday morning I was finally fed up with having a 2002 Ford Monument in my driveway. I've creeped and crawled, poked and prodded, observed and tested over the past two weeks. This is especially difficult because I am a paraplegic and have very little use of my legs. It was easy enough getting down under the truck, gravity still being in full effect. Getting back up was another story. I specifically got this truck so I could haul my electric wheelchair around.

I looked up the name of a local tow service and was searching for my cell phone to give them a call. I was ready to call when I asked my wife to give it a try one more time. She gets in it and truck fires right up! While it was running I took it to the guy I trust to work on my vehicles and explained to him the symptoms and troubleshooting I've done so far. He's going to get it up on the rack and let me know later this week.

Thanks for everyone's help and advice. I have learned so much on this site and have saved so much money. You guys and gals are great.

I'll check back in when I have more information.

 

[JimInRadfordVA]

Well, I'm stumped.

My mechanic hooked up a fuel pressure gauge and the vehicle started and ran flawlessly every day, three times a day, for more than a week. Fuel pressure ran up fine at "key on" and held steady in operation.

He noted the new rollover switch I had installed. The 8-pin connector and fuel pump connections showed no corrosion, but he gave them a quick cleaning and applied dielectric grease as a precaution.

He told me that the only thing he could do was come and check it if it acts up again, and troubleshoot it in my driveway. He refused to take any payment for the time he had in it.

That's it for now. Thanks for following this adventure.

 

[Kjhadfield]

Don't know about explorers but on rangers they have a body to frame connector under / behind the drivers seat that corrodes that kills the fuel pump

A connector or ground? Just because you mentioned body to frame.

This reminds me I need to fix the ground wire in similar location that had crumbled when I touched it