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Hey all. 2004 E-350 Super Duty XLT 5.4 with 97k. Currently I am back to fighting with my Fuel Pump Driver Module. Purchased the van about 2 years ago with 92k. I was having problems with the FPDM and a P1233 code. I rewired the FPDM harness, cleaned up grounds, new fuel pump and sender unit, new spark plugs and ignition coils and it ran like a dream for about a year, or 5,000 miles.
Now I am back to the same battle. Redid all grounds down to bare metal and all new cable this time, and also did new denso ignition coils. After almost exactly 15-20 mins of driving or approximately 5-10 miles, the throttle starts to stutter, then eventually I get random bursts of throttle, bucking and stalling. After clearing code on side of road, I have yet another 20 minutes until it happens again.
Upon figuring I should take another look at the harness connections, It seems that the green/black oxidation has continued to spread. I am running out of wire before I start going into the big part of the harness and I'm really not sure what to do. At this point I am convinced this is my problem unless anyone here has any other thoughts. The white cable and black/orange ground that seems to go back to the other breakout on the harness seem to be the worst offenders of the oxidation. Should I just keep cutting back until I hit clean copper and then extend the connections with new cable back to normal length?
The only other thing I can think that would be a bit easier and fool proof would just be getting a new fuel sender wire assembly (4C2Z-14406-AFR) but it is discontinued everywhere online, and my luck might not be any better at the junkyards of the northeast with all of the rust and corrosion.
I'd physically check the FPDM itself as they've been known to fail due rust forming on the backside where it sits against a metal frame or axle part. Try this link:
There are garage kept cars and trucks at the junkyard
I find vacuum harnesses and other wiring parts that are pristine regularly
You can order that connector new if you look hard enough
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