Code P0232 got me! broke down : (
 

i been noticing randomly that my Expi wont start... but its like 1 out of every 30 starts... and if i try like 4 times, it starts. Last night i come out of the gym...and it wont start at all... Pull codes and i get P0232 - "fuel pump secondary circuit high". so i check fuel pump fuse, relay, reseting intertia switch... still no start... plenty of cranking power, just not getting gas for some reason.... tried unhooking battery for a while, taking tune out, reinstalling tune.... still throwing P0232, and wont start. Had to get a cab home, and had it towed to the local stealership today... waiting on the call. Im doubting i need a new fuel pump at 105k miles... im guessing something is up witht he fuel pump circuitry....just dont know what...
more to come...
anyone experience this, or get this code?

No I never had the code, but from your description it does sound like you'll be needing a new fuel pump.

stealer is sayingits fuel pump... and they want $1000 parts and labor... i told them not to touch it. my local mom and pop shop said they would do it for $500. Im about to give up on dealers... i almost dont even trust theri diagnosis...
This is the same dealer i brought my Cobra to when it wouldnt start this summer... they quoted me $800 to fix. I ended up going down there, buying the part for $150, and installing it in their lot while they all watched me... took me 20 mins. It fired right up, and i drove away staring at them... im done with them... either i fix myself or have the mom/pop shop do it.

At least the dealership came up with a diagosis. What did you pay them for their time in diagnosing it?

diagnosis was $98 plus tax... but honestly, i dont even trust them. I did a ton of reading about code P0232 and nowhere does it say that the fuel pump is bad, it has to do with Fuel Pump circuitry. The fuse, the relay, the fuel pump wiring, the inertia switch... in most P0232 cases i can find on F150 boards, it was cured by replacing the relay or fuse, reseting the inertia switch, or simply jiggling the wiring of the pump around to simulate bumps in the road. The truck is at the mom/pop mechanic right now... they have worked on it before and i trust them... waiting for their call for an update right now...

Bad Fuel Pump at 107k miles! Mom/pop shop got her fixed, name brand aftermarket pump for $300, plus $250 labor, out the door for $550. That is a lot better than the STEALERSHIP! $475 for a motorcraft pump and $525 for labor....so $1000 !! They claimed since i had a full tank of gas they had to drop, they were charging me extra labor...what BS. Just drain it ya dopes...
The mom/pop shop mentioned that running our 30 gal tanks down to E before filling puts extra strain on the pump. He said taking the tank down to 1/4 tank, then filling is easier on your pump...just FYI.

It's not so much that it strains the pump, but rather the pump runs hotter and doesn't last as long. The fuel acts as a heat sink and helps to keep the pump running cool. When you run a tank down to E, the pump is no longer submerged, so it runs hotter.

makes total sense...
im just depressed that my Expi is right at a point where she is paid for, yet starting to rip through parts... 107k miles, and in the past 5 months: alternator, battery, ball joints, tie rod ends, rotors and brakes front and rear, tires, and now fuel pump... now im waiting for the starter and COPs to start failing... no more....pleez!!!

The parts all sound like normal wear parts for the miles on your truck except for the fuel pump but sounds like you know what the issue is there just as Alloro pointed out. BTW exhaust manifold studs are in your near future.

haha... great! thanks for making me feel better!! what happens to the studs? just get rusted and worn and snap? i bet those are fun to get out... cant wait.

Not trying to make you feel bad, but they rust the nut breaks off the you will here exhaust noise like some describe as taping/ticking noise, my 01 is OK so far but my now sold 97 had 3 broken studs at 9 years old and 160K so maybe not near future and BTW the starter had never been replaced and when I sold her last September she was running strong with 192K.

New fuel pump
 

When you said " Im doubting i need a new fuel pump at 105k miles..." I was thinking - fuel pump....nuthin lasts forever anymore.

Yeah, i dont care about the regular maintenance... breaks, rotors, oil, all that crap... i dont even mind small jobs like alternator... i put that thing in in literally 20 mins...very easy and cheap... but when something like ur fuel pump goes, it gets annoying. I was stranded, it was 15 degrees out, 11pm on a Tuesday... had to get it towed... cmon Expi, i take care of u....take care of me! haha

Right around the 100k mile mark, I went through some parts: ball joints, rotors, battery, plugs, etc. Since then, everything has stabilized, I have spent very little money for the last 40k - it seems to happen in waves.

As for the P0232 code and a no fuel pressure (or no fuel pump running) you should check voltage at the inertia switch first (which is easy) then (if voltage there) at the tank selector switch. Test the continuity of the switch. Mine has a bad tank selector switch that set the P0232 code and then the PCM wouldn't let the fuel pumps run. The switch has 6 connections, two hot leads in the center (one for the pumps and one for the gauges) and two pairs of connection, one set for each tank. The switch costs abour $17 aftermarket. I write all this because I never saw this code and problem mentioned together in the forums before.