We have a 2015 Expedition with 109,000 miles. We bought it new in November of 2014. At 40,000 miles the fuel pump gave out so Ford put on a new fuel pump in the tank. Okay we put another 30,000 miles in less a year that fuel pump in the tank gave out again! The fuel pump was in warranty so they put in a new fuel pump. Now we have been stranded on the side of the road on a very hot day! It will not run. So we waited till it cools down a few hours later it started right up and drove home.
We took to a Ford place to check it out. The codes came up and it says the wiring hardness or fuel pump in the tank. They don't know what to do. Because the Expedition is on the third fuel pump. They told us to bring it in on a very hot day.
So we took to other Ford place in different town and they couldn't find anything wrong with it!
What seems to be a problem? I do not want to be stranded all the time when that happens!

 

While I agree the pump should last longer than 30-40K miles, if you live in a hot area and keep the fuel level below 1/2 a tank, the pump will not last as long. The fuel acts as a heat sink and allows the pump to run cooler. With less than 1/2 a tank of fuel the pump is exposed, runs hotter, and fails sooner. Just some food for thought.

 

Is it really 1/2 tank? I have always heard 1/4 tank is where fuel pumps come out of enough fuel to cool them.

 

The fuel pump on my '04 went out at about 80K miles. I had the dealer do the change, flush the system per their recommendations, etc. At 100K miles it went out again. I had it fixed at a different dealer and he stated that the first dealer did everything right and that these things happen. Then he mentioned a bad batch of pumps and the fact that the Explorers were being recalled for faulty fuel pumps.

Keeping the pump submerged is the best practice but whats the point of buying a vehicle with an extended range tank if you can't benefit from it?

 

For the most part the bulk of the fuel pump assembly sits within the 1/4 to 1/2 range. The pickup tube extends from the pump down through that last 1/4 to the bottom.

 

There's nothing saying you can't run the tank down near E when going on a trip, it's just those local around town times where you don't need the range where it helps to keep the tank more full.