Back in January I drove my excursion about 1 1/2 hours or so and my tank had about 1/4 left. I shut it off and went to start it about 15 min. later. It did start but was sputtering. I shut it off and it started back up and ran fine. Drove another 1/2 hour... Shut it off, went to start I and it would only crank. Sounds like it isn't getting fuel. I also tried pressing he gas pedal thinking maybe a faulty IAC but that didn't help.I waited 1/2 hour and it started an ran fine. has not done it since... Always had more than 1/4 tank left. This past weekend drove to the same place pulling my trailer. No issues at all. Coming home I live at the top of a big hill. My tank was at 1/4. Backed the trailer in and unhooked. Shut the ex down and walked away for 15 min or so. Went to put it in the garage and it started and sputtered, it did clear up after a few seconds and idled fine. I then shut it off. Tried to start it again and it would only crank. Waited a few min. and it started and ran fine. Does this sound like the fuel pump giving out?

I have a scan gauge a checked for codes.... Nothing
Garage kept hardly sees rain.
Just over 95 k miles
Only other thing is both times this happened it had sea foam in the tank

Napa says that bosch is the OEM pump. Is there a difference between motorcraft and the Bosch? Is one better?

Could this also be a symptom of a crank sensor going bad?

 

Any ideas! I really don't want to be stranded when camping

 

Next time it won't start, whack the gas tank with a 2x4 - that'll jostle the fuel pump enough to make it run again. If it's the fuel pump.

Check the fuel pump relay too - the relay, when they start to go bad, get hot - leading to less current to the fuel pump, which overheats the fuel pump. The few times I've replaced fuel pumps, it turns out the relay was bad to begin with and caused the fuel pump to go.

Thing is, this could be the crank position sensor too - it gets hot, fails, cools off and works again.

You need to check fuel pressure when it won't start.

 

If you have access to a fuel gauge you can check to see what type of pressure you are getting. You should have 28-30 at idle and 38-40 at WOT.

 

Thanks, I really want to be proactive and fix this rather than reactive and have a major issue when on the road.
How do I test a relay? I am thinking...
to be safe replace the fuel pump, relay and maybe regulator. I could
also replace the crank sensor. I hate throwing money away on un needed parts but if it won't show up all the time what else can I do? I go camping almost every other week and travel at least an hour each way.

 

2002 2wd V10 Excursion. 87k. I am experiencing the same problem. The last 6 months, difficult to start. Wasn't sure what the problem was. Bad injectors, bad fuel pump, dirty filter, blown fuse, bad relay or the regulator. The fuse is good. Only a little gas came out of the valve on the pass side fuel rail when I pushed it. I replaced the dirty filter. I disconnected the blue gas line from the filter and turned the key on and no gas came out of the line. If the filter is working even a little bit, won't fuel come out of the line? Not looking forward to drop the tank unless I know for sure the fuel pump is bad. I also did not see any place where a fuel pump relay is. Only a 20A fuse.

 

not sure as our rv is newer, but had similar experience with it. Stopped to refuel and it would only stutter and backfire etc. Finally it started and ran ok. Got up to almost destination and it started again while merging onto another highway. Dies alongside of road and again restarted got to rv camp and did not shut off got to the site and it never started again. got roadside assistance and a tow the next day after they diagnosed a failed fuel pump. Anyhow, got a fuel pump they installed and still did not start, no codes (place had a diagnostic system with all fords as they did fleet service), replaced tps, gas tank cap, new battery etc, still nothing. after the 2d day one of the mechs decided to replace the inline relay on the frame with one from a deadlined vehicle. VIOLA it started and ran fine so there is a possibility that could be your problem. Not sure if your vehicle has the same thing but give it a look see. Bought a spare at orielly for about $65, ford same price area. AZ and net into 3 figures for it. will look up when I get home for lunch.

 

Pretty sure the EX has the fuel pump relay soldered onto the fuse box, makes replacing it a bit of a pain.
Does the EX eventually start and run correctly? I think that you need to rent or borrow a fuel pressure gauge and verify your pressure at Idle and WOT.
Fortunately, dropping the EX tank really isn't too bad of a job, I've had mine down trice now, once for a new pump (sudden death with no warning behavior) and again for a new hitch installation. It helps if you are near empty either by use or temporary aux fuel pump (what I used) to make lowering the tank easier. There are threads on this over in the EX forum here in the Tech Folder.

 

Thanks for your help WE3ZS and HANK85713. I forgot to mention it will not even start now. Just turns over. The battery is new and the starter is good. Still trying to figure out where the in-line relay is. Any help on the location of it would be great. I think they Ford has put them in different locations depending on the year of the Excursion, I have the 2002. Going to try to hit the tank with a 2x4 and try a re-start today.

 

Ask that question over in the EX forum, I know we have folks there who have had to deal with the relays on various years.

 

similar posting here: https://www.ford-trucks.com/forums/1...er-module.html, looks to be same issue on fuel pump that I posted earlier, just didnt have correct name!

 

Thanks again for all your help everyone. I replaced the filter and knocked on the tank with a mallet and a 2 x 4 and it started right up. {Amazing}. I cut open the old filter that had 87k on it and it was dirty but not that bad. I just ordered a fuel pressure test kit on Amazon. If I use the test kit and I find that the pressure is not up to the correct specs, how would I know if it is a weak pump or the regulator?

 

you tube videos has a lot on the module and fuel pump issues. just type in your problem https://www.youtube.com/results?sear...+pump+problems

 

I got a 2012 F550 with relatively low miles 6.8L V10 and it does the same thing: Cranks forever with no start. I changed the fuel issue to its dead end, new fuel pump, new fuel pump controller, fresh gas, all to no avail.
I think it's a spark issue - what could it be? Cam position sensor? Crank position sensor?

I've had the problem for 2 years and it's completely frustrating. It used to start after a minute of cranking, if a gas pedal got hit. Then next start would be smooth, if within a few hours. But let it seat for a while and the next day back to the same crank-no-start issue.