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Strange Intermittent Stalling Issue

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Old Oct 24, 2025 | 03:08 PM
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Strange Intermittent Stalling Issue

I hope someone smarter than me can help with this. I have a 2002 F250 SD 5.4, automatic with 160,000 miles on it. In the last year I have experienced a random stall while driving. Not while idling or any other time, just while driving down the road. It is a sudden cut out with the tach going to zero instantly and with in 1-2 seconds it recovers on its own, no need to turn the key to restart. It will do it 2 or 3 times in the span of approx 3-4 minutes and then just drives like nothing happened. It's only happened 3 times in the last 10 months which is very strange to me. Its not a loss of fuel I believe, because it doesn't sputter or slowly buck and die, it just flat out dies like you turned the key off. Someone had suggested to me the CJB (fuse box) that has the tiny fuel relay may need replacing because its built into the circuit board. If the relay shut down the pump, I would think it would stammer and sput till the remaining fuel was spent before it would stall.
Could it possibly be an electric issue, maybe whatever feeds the spark to the coils?
No check engine light
No codes
I replaced the Throttle Position sensor and the Crank Position Sensor.
 
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Old Oct 25, 2025 | 11:26 AM
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When that fuel relay cuts out, there's not sputtering, just dies. Yours may be going out. The only way to really know is to be able to test fuel pressure or test that there is power on the right circuit when it happens which is annoying to try and time. Go check out the v10 forum. There a few threads on this with fixes. The v8 system should be the same.

It could be something else, however, since yours comes right back and my experience has been that it is dead until the relay cools enough to work correctly again. But you could be on your way out and this is just the start of longer down times. Either way, sounds electrical. I've had to bypass/rebuild several circuits on my '02.
 
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Old Jan 25, 2026 | 02:06 PM
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Originally Posted by cokeman
When that fuel relay cuts out, there's not sputtering, just dies. Yours may be going out. The only way to really know is to be able to test fuel pressure or test that there is power on the right circuit when it happens which is annoying to try and time. Go check out the v10 forum. There a few threads on this with fixes. The v8 system should be the same.

It could be something else, however, since yours comes right back and my experience has been that it is dead until the relay cools enough to work correctly again. But you could be on your way out and this is just the start of longer down times. Either way, sounds electrical. I've had to bypass/rebuild several circuits on my '02.
You were correct, it was the fuel relay that is soldered on the circuit board for the fuse box. I sent mine off to Circuit Board Medics and for $250.00 they fixed it, it works like a charm now.
 
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