My 2002 F250, 5.4L started stalling randomly. It will always restart after 2-3 minutes. All electrical systems are working when it dies. It can happen at highway speed, in town or at idle. There is no warning, such as a shudder or hesitation, the engine just dies. The problem was intermittent at first and it could be 1 week between incidents, not it is more persistent and when it happens it will crank after waiting a couple of minutes, but then happen repeatedly after driving a short distance. After sitting overnight, it might crank and run all day without a problem.

So far I have replaced the fuel pump, CPS, fuel filter and cleaned the throttle body and MAF sensor. I took it to the dealer and they replaced the IAC valve.
The problem has continued, but is still somewhat intermittent.

The guys a AutoZone did not find any codes. I ordered a bluetooth device so I can see the sensor info in real time and will have that tomorrow.

Until then, does anyone have any ideas that will help me troubleshoot this problem? I need to haul a backhoe across town!

 

Fuel pressure maybe? Try a new fuel cap or leave the old one off for awhile - may thow a code.

 

How old are the ignition coils?

 

I took the fuse/power block out and looked at the back of it. One of the relays soldered in to the circuit board is burned. This is the fuel pump relay (not replaceable). Looks like I need a power distribution box.

 

. I have same truck with this problem. Did you find a resolution?

 

I let the dealer try to find the problem and they replaced a couple of parts that in hindsight could not have caused the symptoms. I finally figured out it was the fuel pump relay which is sandwiched between two circuit boards in the fuse block. The Fuse block is no longer available and I could not find a used one. I sent it off and had it remanufactured since it required desoldering dozens of connections to decouple the circuit boards. I can't find the name of the place I had it done, but check this listing on eBay https://www.ebay.com/itm/29304195421...oAAOSwdwVcURMQ.

Good luck

 

Thank you sir!!

 

Trey, I have the fuse block out and disconnected. Did you remove the back cover to expose the circuit board to find the burnt relay? I can’t find a video on this and am hesitant to remove it not knowing what’s under there.

 

I’m adding my comments here from another thread on this forum.

I’m having the same problem now in my 02 F250 5.4. Did you ever resolve the issue?

UPDATE:

The engine shut down while driving again and wouldn’t restart. Good news is I finally got an error code (P0231- Fuel pump secondary circuit). Now, from these threads it sounds like the relay is not replaceable and soldered into the circuit board within the fuse block. This is fixable though and I’ll update again with what was done.

UPDATE #2:

The random stall issue has been fixed. I had one of two options. One is to remove the fuse block and ship to a company that repairs automotive circuit boards. I found one in South Carolina and one in Missouri. This fix is a one time fix with a new relay being soldered in.

The second option was to bypass the circuit board and install an external relay with an add-a-fuse set up and the relay. My shop owner friend did it so I can’t give the technical aspects of the rewiring. There is also a YouTube video of this repair on an 02 F250 5.4 that was pretty detailed. I liked this option because if the problem reoccurs, I can replace the relay myself.

 

Hi Guys - The engine in my 2006 E250 would stop running randomly. Whether on side roads at 35 mph or on the highway going 70 mph. Coasting to the side of the road and turning the key off then on again the engine would bubble back to life. Sometimes while traveling at highway speed, I was able to put the tranny in neutral and turn the key off then back on and the engine would restart. (Dangerous ! Don't do it !)

I brought the van to TWO mechanics to fix this random problem. They checked the codes that pointed to the throttle body and throttle plate position sensor. But they found nothing wrong. (???) Read on...

My son and I were going on a 200 mile RT trip and wanted to get this fixed before the trip. After a couple hours of internet and shop manual research, we attacked the problem and removed the throttle body and found the throttle plate was very sticky!! (It was very obvious and wondered why the two mechanics didn't see it ?) Using WD40 and a rag, I kept spraying and working the plate until it was loose. To be sure we solved the problem, the throttle position sensor was replaced too. ($65 at Autozone.) The next day we made the long trip while towing a trailer and the engine ran beautifully !!! Not one hiccup ! Even the engine light on the dash went off.

It was an easy fix. I don't know why the mechanics didn't pick up on it. The codes all pointed to the throttle body. I hope this helps some of you and you're able to fix your engine.

- Jimi -
Harvard, MA