I am Tired of this Happening!!!

[mgv366]

Ok.. I've posted before about this but nothing suggested has worked.
My damn Fuel Pump Relay keeps cutting out and the truck stalls. It doesn't happen with any regularity. Purely random.
The fix is to open the POWER DISTRIBUTION box and "jiggle" the relay and the truck starts and runs fine until the next occurence.
I've replaced the relay several times with no avail. Is there a chance that the is something wrong with the plugs where the relay plugs into???

 

[Brock94]

I have no experience with this, but common sense says that there could be corrosion or damage in the connectors and wires in the power distribution center. Also, maybe one of the connector terminals for the relay is out of position and not fully engaging on the relay terminal resulting in an occaisional disconnect. I'd take a really close look at those terminals and wires where they connect to the terminals in the distrib center.

 

[DeRocha]

I would also remove and clean all ground connectors going to the fender etc to ensure a proper ground is maintained... Many times oxidation creates a film on the contacts causing higher resistance...This will often cause sporatic problems as resitance can change with temperature and vibration.

Basically you need access to the Fuel pump relay terminal contacts when the failure occurs so you can troubleshoot the failure. As such I would make a temporary fuel pump relay wiring harness (so the relay will be connnected to the power distribution box by wires instead of being in place). Cut several lengths of wire (one for each connection on the relay) and crimp an insulated male and female terminal on each wire (bring relay to store if to determine correct size). Wire up the relay to it's corresponding power dist box positions (double check and ensure correct wire placement). Use electrical tape on the relay to ensure NO accidental contact is made between the terminals or any metalic part of the X. Recheck the positions and verify the car starts. Now whenever the fuel pump dies you can probe the contacts in the power distribution box to see if there is a problem with the wires actuating the switch 12v signa/ground, or the wires used for the power/load(fuel pump).