1998 ford explorer 4.0 blown fuel pump fuse
 

The fuel pump fuse on the explorer keeps blowing when I try to start it. Where should I start looking?


Thanks,
Darren

You can try replacing the fuel pump relay, but I'm not sure if a faulty relay would cause the fuse to blow. Normally, a faulty relay just results in the pump not running.

Heres how a 97 is wired, yours is probably the same: PDB fuse 3 to relay to inertia switch to fuel pump. Try opening the inertia switch & see if a new fuse blows.

thanks, i will test out the fuse with the inertia switch open and closed tomorrow.


Darren

I opened the inertia switch and put a new fuse in, then turned the key on. The fuse did not blow. I then closed the inertia switch and then turned the key on and the fuze immediately blew. I am assuming now that there is some kind of wiring problem after the inertia switch, or the fuel pump itself.

I do not have a manual for the Expy, does anyone have a wiring diagram for the fuel electronics?

Thanks,
Darren

The 97 EVTM shows from inertia switch to fuel pump is wired pink/black stripe.

Theres a connector that appears from the diagram to be under the drivers side floorboard.

If you open that connector & a new fuse does'nt blow, theres a short in the PK/BK between there & the pump or possibly the pump is locked up.

Have you tried giving the gas tank a good whack with your hand? Sometimes that will bring a bad pump back to life temporarily.

I will try opening the connector first. I will also try a whack on the tank.

Thanks,
Darren

how many wires go into the connector and how many come out? I found one that is grey, but I am not sure if it is the right one.

Darren

Just pink/black, try following the wire from the tank.

I found the connector. I disconnected it and turned the key and the new fuse did not blow. Now I am assuming that the pump is bad.

Darren

Is that connector under the dash or under the floorboard? The wiring diagram isnt clear on that. If it's under the dash, take a look at the wiring where it goes thru the sheet metal to the underside of the truck.

Also there is a connector at the tank with 6 wires that you can disconnect & see what it does.

I bought a haynes manual to find the connector. It is located right under the driver side door on the inside of the frame-rail. It has multiple wires going in and coming out of it.

Next I am dropping the tank and will disconnect the connection on the sending unit.

Darren

After looking at the wiring I found a bare power wire (the brown and pink wire). It was right before the connector that goes to the sending unit/fuel module. I repaired it and all seems to be working as it is supposed to.

Thanks for your help.


Darren

Good deal, glad to hear you got it fixed.