For starters I would like to say thanks in advance for any replies. I have a problem with my 95 Explorer not starting. It turns over just fine but will not start. It has done this twice before but, after going back a few hours later and trying, it fired up and done fine for several weeks before it happened again. This time it never started. From reading here and several other places I have tried several things to diagnose the problem. Here are some things I have tried or know.

I have checked every fuse and all are good.

I turn the key on and pull out and replace relays and all click but the fuel pump relay.

With my ohm meter grounded to the battery the fuel relay has 12 volts on two pins, 3.5 volts on one, and 2 volts on the last one with key on and 0 volts on all them but one with 12 volts with key off.

I checked for codes and the only code I get is 542 (O,M) Fuel pump open, bad ground or always on - - Power / Fuel Pump Circuits

I stuck a paper clip in the fuel pressure thing that looks like a bicycle stem and nothing came out.

I checked the fuel emergency switch and it was not tripped. I tapped on it and tripped it several times and rest.

Fuel emergency switch has about 9.something volts on one wire, about 12 volts on another, and 0 volts on one which im guess is for the dash light.

I unplugged the wire connector going to the gas tank which has 4 wires I think. One has 9.something volts, one has about 12 volts, and the other 2 has 0 volts.



From all I have done im thinking bad fuel pump. Before I go and take the gas tank out and buy a fuel pump I wondering if anyone thinks it could be something other.

Is the wire at the emergency cut off supposed to have 9.somthing volts? The one wire going to the tank has the same. Is this right?

Any surprises to look for when dropping the tank?


Any questions you have on something that I may have left out here just ask and I will try my best to provide you with the answer. Thanks for any help on this. Its driving me crazy.

 

Got the tank dropped to the ground. On my way to get the tool to remove the fuel lines so I can get the pump part the rest of the way. Im going to get a new fuel filter and new pump since I have done went this far. I will post back after I do some more testing just incase someone else has this problem. Some of this might be helpful in fixing their problem.

 

Hooked power to the pump when I first took it out of tank and it seemed to run great. Waited a couple min and tried it again. Pump didnt run. Barely taped it and it started up. Tried it several more times and it ran but once out of 10-15 times it would not start up until I tapped on it. A couple of the times when it was running it seemed kinda sluggish. Anyway, put in the new pump and put everything back together and it fired right up. Had pressure to rails. Also I did notice the fuel relay is clicking but just for the 2 seconds when I first turn the key on and im guessing right back off untill starting. Thats the reason I didnt notice it before. Thanks for all the help. Maybe someone with the same problems will find this thread and might get something useful out of it. One last thing, buy the plastic tool for removing fuel lines and save yourself a whole lot of trouble.