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We just got our 2007 Ford Expedition Limited back from the Ford dealer; they had it in the shop for 27 days!!! The initial problem was that the truck would crank, but not start. After about 3 weeks of "checking everything" they decided to replace the engine control module; it didn't fix the problem. They ended up flying in a Ford tech; he couldn't figure it out. They flew in ANOTHER Ford tech and he determined that it was most likely the fuel pump. The dropped the gas tank and found that the fuel pump had melted to nothing and the cabling going in and out stretching about 1-1/2 foot away had also melted. Per the Ford tech; "You're lucky you had a full tank of gas, otherwise the truck probably would have exploded." When asked what caused the failure, their response; "We have no idea". They also replaced the control module; which had also failed. They socked me with a $1310 bill to replace the fuel pump. The control module was replaced under warranty to "help me out" after the fuel pump bill.
My main issue is that there was a short that caused the fuel pump to melt to nothing and create a potentially deadly situation for my family. I’m not satisfied with their response that they have no idea what caused the problem. I'm trying to find out what exactly the engine control module controls. In the repair order it is listed as “7U7Z-12A650 DRA Module – Engine Control”. If the control module is responsible for electrical control of the fuel pump; then this could have created a faulty control issue with the fuel pump causing it to fail. There were other indicators leading up to this. About 6 months ago, my wife noticed that when she plugged her cell phone charger in the outlet, it would turn the A/C off. About 4 months ago, the truck would not start – similar conditions. The battery was replaced and the truck started working again. I’ve looked around the Internet trying to find data on this, but I’m at a loss. I really need to find an answer to this. The fact that Ford cannot determine what caused it equates, to me, that they cannot guarantee that it’s not going to happen again and we may not be “lucky” enough to have a full tank of gas the next time. After buying Fords since 1986, I'm absolutely disgusted that they assumed such a nonchalant attitude when they told me that we were lucky it didn't explode!
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