I can"t beleve this!
After weeks of problems with starting, I think I have found the problem.
2002 sport trac 156,00mi. Droped the fuel tank to replace fuel pump.
On inspection of intank unit found _PLASTIC_ hoseline to pressure regulator cracked at coragations,(like a flexable drinking straw) before the inlet to the pressure regulator unit.
If there is a hole in the line I would think the fuel pressure would dump and not be able to pressure the fuel rail!
Have a new assembly on the way, would be goofy not to replace the unit after all the work of droping the tank.
I almost would like to replace the coragated plastic line with rubber line and see if I am correct.

What do you guys think! (Think of the hardships due to poor design)

 

I'm not sure you can say the design is poor because of this, I've not heard of this being a common issue yet. If the design were "poor" there would need to be a trend of failures....

Most modern cars now use a plastic fuel line. From my understanding, this is primarily due to the use of ethanol in fuel. Standard rubber fuel line is not compatible with ethanol, so continuing to use rubber fuel line with modern fuel would be a poor design.

I'm not getting a clear visual of where the crack is that you found, but if it is at the inlet to the fuel pressure regulator, it does seem like that would prevent the fuel system from properly pressurizing. I'd also agree that given the work to drop the tank and with the age and mileage of your truck, it is probably in your best interest to change the fuel pump out since you have one ordered anyway. If you decide to return the fuel pump, be sure to use anti-seize on the bolts when you put everything back together.

-Rod

 

Thanks for the reply. Did not think of the make up of fuel now days,I agree that some stuff will brake down.
After I replace the unit I do intend to make an emergency fuel tank with the unit I removed.(portable)
I have a 12 gal boat fuel tank that I'll put the fuel assembly in and make up hose using aircraft qualty parts that I will be able to hook up to the fuel rail or fuel filter inlet. Depending on the fuel system being returnless or not, so as not to have fuel returing to the trucks fuel tank.
This should be enough supply fuel to get home on rather being towed.
Sound like it will work?