2005 F150 with 60k miles wont start first thing this morn. It cranks just fine but wont start. Upon closer inspection the fuel pump doesn't activate when the battery is turned on, or ever for that matter.

I popped off the fuel pump driver module and tested the white switched wire that comes from the inertia switch and it had 13.5+ volts. Took a spare battery and i jumped the two (+) (-) leads for the fuel pump in the harness and the fuel pump worked.

Got a new fuel pump driver module from the dealer for $138 and the fuel pump still doesnt turn on.

I started to get pretty miffed at the situation and followed the wires back to the harnesses under the drivers door. The harnesses are protected by the plastic shield, so i took that off (it was full of dirt and crap) and popped open the connector. The white switched wire is positioned at the bottom and was visibly corroded to a green color. All the others appear good. So i pulled the white wires out of the harness and attached a jumper wire.

Fuel pump still wont run.

checked the two wires in the middle of the FPDM. Monitor and Control wires i think is what all data said. The monitor wire- the one on the side of the nipple for the harness- shows 13.5v, other shows nothing.

Anyone have any ideas? I'm really stumped.

If the FPDM is getting power. and the leads in the FPDM harness to the fuel pump work fine when jumped with a spare battery. And it's a brand new FPDM. What else is there?

no trouble codes either.

thanks for any help anyone can provide!! I'm racking my brain and i'm about out of ideas.

 

Check the fat black wire that goes into the pump control module connector.This wire supplies the fuel pump ground to operate the pump.If this circuit fails,the pump will not run.I would suggest rather than testing this wire (an ohmeter will not tell you how much current the wire will withstand and will read the proper resistance even when there is only a small strand of wire left,which when loaded,will not move any juice)just run a temporary good ground from a clean spot on the frame and connect it to the black wire near the connector.If the truck runs now,just diagnose the bad ground and fix it.If the ground test did not help,you might have a bad new part.Another problem might the fuel pump control signal from the PCM.There could be a wiring problem or possibly a bad PCM.Also,there could be a missing input to the PCM that is needed before the PCM will command the pump to run.You will probably need a GOOD scan tool and/or a GOOD Ford tech to find these problems and fix them.I would temporarilly hot wire the pump to run and see if the truck will start.If it will not run then,getting to the cause of the no start w/ good fuel pressure might help to find the real issue at hand.

 

Turned out to be the white power wire to the FPDM was corroded in the door-sill . For some reason the door-sill there was full of water and that wire had the insulation nicked off and was corroding.

The white wire still was intact enough to tell my multi-meter the wire had 12v, but the wire wasn't intact enough to run a load through it.

thanks for your help thumper

 

That's good news.I learned a long time ago not to trust test lights and meters when checking power and ground circuits.One strand left of a 50 strand copper wire will test good but will not power up the circuit in question.