Help With Sticking Fuel Pump Relay

[mikeinpa]

I own a 91 XLT and in the last 1 1/2 years I've been having problems with the fuel pump relay. The first one started sticking, but would eventually shut off (after about a minute), this was before I knew about the relay. After it failed open (stayed on all night) and drained the battery I learned about it FAST. I replaced it with a new one from the Ford dealership and within about 6 months it failed, only this time it failed open (no fuel pump). So off to a different dealership for another new one. Ive had it in about 9 months and now this one is starting to stick. A light tap on the relay corrects the problem and it doesnt do it every time I shut off the ignition.

Anyone have an idea as to why these things are failing so often? I think I can rule out a "bad batch" because they were from different sources. Is ther something else I can check?

Any help is appreciated, this is getting expensive!

Thanks in advance,
Mike

 

[jimbo74]

check the wiring.... maybe something isnt wired correctly, leaving you to believe the really is bad eventhough it may not be......

 

[Big Poppa]

Which of the three relays is the fuel pump relay? I tried replacing it, but it still doesn't "click" Are there any other typical problems that would cause this to happen? If the pump was bad, the relay would still click, right? Is there any way to test a relay?

This is for a '91 also

Thanks

 

[mikeinpa]

BigPoppa, Im not sure which relay it it to be honest. Ive had mine out of the holders (under the fuse block) for so long I dont know what order they were in. Mine was black. I can give you the exact part number on the relay tonight after the my "Ex" brings back my X, LOL. I have had them stick open and closed, sticking closed drains your battery, sticking open wont start.

as far as testing the relay Im sure there is a way. Im also sure you could just jumper the pins in the harness (FOR TEST PURPOSES ONLY) to see if the pump runs. Im assuming yours wont start.

There is also a fuse that is inline with this relay, make sure it is good. The fuse block diagram is right on the cover.

 

[Big Poppa]

Ya- that would be great if you could let me know the part number.
BTW the three harness' are different lengths, so they will only go back in 1 way
Do you know which pins I would jump to test the pump?
Ya, it won't start- only click from relay is the middle brown EEC relay (I think it's the EEC) and no noise from the pump.

Thanks

 

[Opera House]

Relay

Should have a pin diagram on top or side. If you pull out the fuel pump fuse you can easily measure current. Normal is 4-5 amps. Many crimp connectors fit in the fuse socket clips. I have a set of test leads made from the U screw connectors with one side cut off. This lets it fit in mini and maxi sockets.

 

[mikeinpa]

Big Poppa....I looked at the box for the relay and it states the following:

DY-867
F8PZ-14N135-DA
Relay

The relay itself is black with Made in usa-24 stamped on it. It also has the following numner 1A22 engraved into the plastic but you wont be able to see this number unless you unplug it from the wiring harness.

Hope this is of some help.
Mike

 

[mikeinpa]

Big Poppa...I was just under my hood and my relay was mounted closest to the fire wall when in its normal mounted position.

I also noticed that I can get mine to turn on by pulling on the wiring harness, guess I'll be chasing down a bad connection. I dont think that is normal.

Im not crazy about there always being power to this relay and Im wondering if anyone has ever installed a fuel pump cutoff switch under their dashboard to disable the pump remotely? Seems like it would just involve breaking the power to the relay, maybe in the line between the fuse and the relay.

 

[Big Poppa]

Thanks guys-
I'll be working on it this weekend-
Does anyone know of anywhere in particular there could be a bad connection?