Hey.

2001 ford excursion 7.3l.

Symptoms: died while driving. Lke it ran out of fuel. Seems to be fuel making it to the bowl. Not alot though (there is fuel going to the bowl). Fuel pump sounds really weird, like surging and inconsistent noise. Kinda sounds grindy or unusualy noisy. icp, ipr, pw seem normal, truck has oil. Good voltage and rpm (all forscan). No codes. Truck seems to be trying to start as far as the pcm is concerned. Trying to start the truck will sputter, like it want to start or fires on 1 piston.

Backstory: I did some seals on the fuel bowl yesterday. It was the seals for the 4 lines going in and out of the fuel bowl. I did have the fuel bowl out and cleaned it. I dodnt take anything apart in the fuel bowl. There were some minor leaks so i was trying to fix those. I was doing a power steering gear at the same time. Pulling out of the garage it was dying but kept running. I got it to the parking pad and it came back to life after revving. Filled the fuel tank and drove it back home, no issue. This morning fired up no problem. Drove around town and no issue (some wot runs to flush the air in the fuel out). Head to the farm with a dump trialer and she dies cresting a hill. It died slowly, like it was running out of fuel. Flat towed it the rest of the way.


What i think:I feel like it something with the fuel bowl. Ill get some fuel pressure reading too after Christmas. I know there is some check valve that can act up. Fuel pump sounds weird, so depending on pressure ill get a new one. Its 5 years old and probably around 50k miles, and a napa special. It is like fuel cant get to the bowl, or maybe to the injectors in full form. Icp started to leak oil, but its reading normally, and no difference unplugged (this started sometime this year).

Mods: aftermarket second tank (both tanks dont work, the this counts as hutch the hutch mod), aftermarket fuel filters, no filter restrictions indicated (there is a gauge). Mostly stock motor.

Looking for thoughts for when i go back to look at it. Dont wanna do the parts cannon approach, but i need my truck. Ill report fuel pressures as that will be a big diagnostic step. Thanks in advance and happy holidays.

 

Based on the information given, fuel pressure would also be my next item to check.

 

Look for leaks around the fuel bowl. Also, make sure you put the pressure regulator housing on the driver's side of the bowl back together correctly. If pump is making funny noises, that might be it.

 

Thanks for the advice. The more i think about it, its probably as simple as the pump.

I will check pressures first, but i think i know what ill find, virtually no fuel pressure. I can run hose to a gerry can to eliminate my contraption of a fuel system, but it has never been an issue. Thinking back, there has been some recent stumbles the last week or so when cold (real winter cold). Maybe when i drained the system removing the bowl, that was its last hurrah. Its also easy to get at. Ill get new pre filters for giggles too. Local parts store has a bosch pump in stock that i may just preorder.

I think its time i get some gauges as i bet i would have noticed an issue and not stranded myself. I like the cts, but the sensors are expensive. She is a 25 year old relic though and earned some love.

 

I went with a cheaper glowshift fp gauge that has served me well for 2 years now.

Went into the post filter port off the fuel bowl. Need to get an adapter for the sending unit to the ORB.

 

Start with the obvious. Fuel pump making odd noises? Fuel tank full, or do you need to add some to eliminate the question of whether the pickup fell off or not? Take it from there.

 

Why does everything suck?

So everything points to the fuel pump. No issue getting fuel from the tanks. No fuel pressure. No obvious reason other than the fuel pump. Fuel is barely making it into the fuel bowl.

Oh, so thinking ill just bring one, got one on boxing day. Nope. The protective cap on the inlet is broken and in the fuel pump. Good thing i noticed. Also missing pieces (which i could steal from the old pump, but there is a copper washer). So back to the parts store to be mean, and then goto another to get a fuel pump with all the parts.

So good news...its the fuel pump. Drain valve is also leaking profusely now. So ill get a dorman one for now. Get a brand name one some time and swap it when i do the filter next.

Bad news, i tried a different place new in town other than napa (my goto), and got burned. Eff sakes. Even told the lady it was missing pieces, and she say "well this is the fuel pump it says on the computer". Should just left it and walked out. Lesson learned.

 

I bought the Premium fuel pump from O'Reilly's, not cheap at $200

but, the truck was 30 miles away from nowhere in the desert of Utah, and round trips take a long time, and are hard to do if you need to borrow a ride....

No Regrets either, Lifetime Warranty on it, but it has never failed once in two years.

as for Suction leaks? I zipped that up tight, installed a Sump with a Wix 24006 PrePump filter.

 

When I needed a new fuel pump like *now* I grabbed a Carter from the local Vatozone. Has been fine for many years.

I 100% recommend a dedicated fuel pressure gauge. Cuts diagnosis in half and then you have a clue when to change the fuel filter.

 

Welp. No luck. New...new fuel pump sounds the same. No change in symptoms. Pump really sounds like its struggling, varying in rpm and noisey. Still tries to start. I would say its quieter so perhaps there is a more long standing issue showing its face?

So either fuel cant get to the fuel bowl or pump, or it cant return and airlocking? Just stuck that it was allegedly fine until i touched the fuel bowl.

Tomorrow im going to bypass the old vege system and see what that does. Fuel comes out the tank, i can siphon it, and the pre filter is bypassed. Try and find out where the restriction is by elimination. If that does nothing, then i guess the fuel bowl is coming out to check that out. Could one of those viton seals cause an issue at the regulator or something (i just replaced them when this "started" happening)?

Ill check fuel pressure again too but fuel is still barely making it to the bowl.

Imma going to order a permanent fuel pressure gauge...just sounds like a really good idea.

Ill report back.

 

https://www.ford-trucks.com/forums/a...3&d=1727391262

Here is a document I created when struggling to find my fuel pressure issues.

Follow the steps you will find your problem.

 

I'm starting to think the in-tank fuel screens are clogged. Testing for that is fairly simple.

Get a container of clean fuel and run a hose from the intake side of the pump into it. Ya can't drive around but hopefully it will sound better when you rev it.

If that works you can temporarily clear out the screens by blowing shop air back to the tank. The real fix is Hutch and Harpoon mods.

 

i will get the parts and do this. Look like a local shop has most of it.

 

I have no intank screens. I have also determined its easy to get fuel from the aftermarket tank (this is my primary tank). My system is hutched an harpooned effectively. I can easily fill the stock tank up, and i have no factory fittings until the fuel bowl. Really nothing from the tanks to the fuel bowl is factory. The after market tank just has a hose bib at the bottom, and fuel pours out of it and its easy to siphon. The factory tank has a whole new aftermarket pickup (a hot fox i think) and has no screens of any kind. The next thing to rule out is the manifold that switches fuel tanks. Once that is bypassed, the pump is directly hooked up to the tank and should rule out anything to do with the aftermarket fuel system.

That said, im going to follow the link above to try and get some hint on where the issue is so i can narrow down my issue.

The mainfold switches both the supply and return lines to the appropriate tank. Its very easy to bypass, and would atleast confirm its not that as its a big wild variable no guide accounts for. Its possible its malfunctioning and isnt allowing fuel past it.

To stress, this trucks under body fuel system is completely different from factory. Ill take some pics for prospective.

I wouldnt recommend this fuel system, granted its old, i think the po installed it in 2013. Its not high quality like some of the other systems. The tank has held up well and fits good i would say, but that is the only part i like. The worst part is it the fill vents are to atmosphere, and it always smells like an old tractor, and can **** fuel out while filling. I have also clogged them with mud before. The vents should be tied into the filler neck, but the aftermarket tank i dont think has a secondary vent like the factory tank.

 

Add a Discriminator Valve to that breather that is open to atmosphere. That will stop the fuel from flowing out while filling.