Fuel Pump Intertia Switch connector melted!

[jacklad]

I've been having problems with my'03 XLT - originally thought it was fuel pump, but turned out that intertia switch had been triggered - switch was reset, and car was fine, until it happened again - car started on reset, but problem with switch continued - finally decided to put in a new switch - when I removed the old one (after disconnecting the battery) I saw that the connector end of the wiring harness was melted and blackened - switch socket seemed fine - I went ahead and replaced the switch, as the connector still fit despite being slightly warped - switch operated fine (I actually tripped it before installing to make sure reset worked)

So now I need to figure out what may have caused the connector to fry (hoping it had something to do with old switch, not electrical connection)

Any ideas?

 

[justchecking]

Mine did the same thing. For me it was the fuel pump. After your engine has been running a while, open the fuse box under the hood and feel the fp relay and the high beam relay next to it. If the fp relay is hotter than the high beam relay then your fuel pump is going bad.
Check it soon or you'll be replacing that harness and switch again.

 

[BrooklynBay]

http://explorerforum.com/forums/showpost.php?p=2002282&postcount=10