Reaching out to make sure I'm considering everything.

2006 XLT 4.0 L V-6; 153K on the clock, had my first inertia switch trip event recently. Took me awhile to figure out, as FORSCAN wasn't indicating any codes, and the crank/no start/no fuel scenario was driving me crazy.

Spent a couple of hours in here reading posts, learned of the inertia switch, went out, and that was the issue. Took the truck for a short drive, returned home and same crank/no start issue repeated...this time without the inertia switch tripping. Went out an hour later, truck started, no problem..

Decided to run FORSCAN again, and again no codes. Bought a replacement inertia switch unit and was going to replace, thinking original unit is 18 years old, and things do fail over time, started to do so and found connector plug to the inertia switch is melted and deformed.

I replaced the fuel filter 1K miles back, and before I start thinking I have to replace the fuel pump (again, no fault codes), what else should I be looking at? Tried to keyword in all the posts, and could not find something close enough to my present issue; apologies if this has already been answered at some point.

As an aside, I'm 67, haven't turned wrenches in 20 years, but remember a few things. Truck is kept in excellent physical/mechanical condition; not willing to turn it loose on the parts-changers...thanks in advance.

 

I had a nice 2004 Edge that had the same thing happen. I can't remember the details (I'm old too) but I jumpered the terminals on the connector until I found a switch. I would think Ford would carry the pigtail since it is a safety part but not sure. I wouldn't work on anything else till you get this fixed because it may be most of your problem. Not sure why they melt like that unless connection isn't good to begin with and if that is the case it could be your fuel problem because that switch is directly in the pump circuit. It was several months before I finally got around to replacing the switch. Just wanted to make sure it was good in case I sold the truck. You can probably get a pigtail at a junk yard if you feel you must have the switch and can't find a new pigtail.

 

I appreciate your reply. Both cutoff switch and connector no longer available from Ford.

Aftermarket switch in Standard Products (FV10) and connector (Motorcraft WPT1001) available at Rock Auto. Have ordered, expect receipt later this week; hopefully this will resolve issue.