52k on it and it got a code a couple weeks ago saying three possible things. Fuel pump, fuel filter, or fuel rail sensor. I'm going to lay under my buddy's truck split the line (change the filter while I'm down there) and see if it's the pump or filter, but I'm curious if there is anyone out there that knows of any known problems like this before we waste our time?

He's been running E85, has anyone heard of problems with flexing fuel, or more moisture in E85 (just reaching a bit)?

 

Since the oil companies were mandated to start putting 10% ethanol in gas, i have been getting 3 codes, both banks running lean and one unknown, it makes it idle rough but thats it, never ran e85, i wouldn't unless thats all there was. Ehtanol does turn to water over time. I would get the sensor tested if possible, it sounds a little to early for the fuel pump or filter to fail.

 

is his truck a Flex Fuel?
if not, the E85 is very corrosive and eats seals...could get expensive quickly

wierd though

 

@dlGentry

your truck is an 04 right? the early 04 models had a very restrictive ECM strategy. sneezing wrong at them could cause a CEL. may want to get Ford to update your PCM to the newest strategy

 

Can you pull any codes? That may give some direction. If the truck is not designed to run E-85 that could cause problems. The E-85 is very corrosive on the entire fuel system. The rails, injectors, pumps, and seals are especially vunerable to failure running E-85 in a vehicle not designed for it.

Greg B

 

Update, It's an 07

Fuel filter is fine, CEL code is P0191 something to do with the Fuel rail pressure sensor.

When I was changing the filter, turning the key to the run position did not result in fuel coming out of the fuel line. Found that they gave him the wrong filter, but blowing through them gave the same resistance (yeah, very precise). Then after I crawled out from under the truck, tried cranking it over (figured the fuel rail might have enough pressure to trigger the pump) and then the pump kicks on after the starting timeout (about 15sec). Pump sounded like crap at first, but we had fuel so we drove it back from where it was stranded. Then while reading the codes, I heard the pump constantly running while the truck is off and the key is in the run mode, So now I'm curious if the sensor is reading low and making the pump run all the time at max voltage causing it to burn up. Any suggestions about where the sensor is (I haven't even popped the hood yet) or if I can just clean it or replace it?

 

Truck is definately a Flex fuel motor.

 

Anyone know if the fuel pumps are the same for flex fuel and non-flex fuel? Autozone has the 4.6 and 5.4 non flex as the same part number, but nothing for the flex fuel pump. Between that and the sensor, I have a feeling he's going to have to grab his ankles at the stealorship.

 

If he can wait a few days...there are a number of online parts places in the sponser link above that will sell you ford oem parts at MUCH reduced prices....

 

If I can't get them from Autozone, he may just have to wait. Besides looking at the weather and my schedule up until Thursday he may have to wait anyway.

 

I had a p0191 code on my wife's 02 Taurus awhile back. I checked into it and replaced the fuel rail pressure sensor. Low and behold about a month later the car wouldn't start. I took the scanner to where the wife was stranded and pulled another p0191 code. Only this time the dome light went off with the door open when she turned the key to start. I went home and grabbed the battery out of the Mustang and threw it in to start it to get it home. I checked the battery in her car and as I suspected it was shot. I replaced the battery and cleared the codes and haven't had any other problems since. That's been 6 months now. I'm not saying that's your problem, but now I always go by the book diagnosing these things, because I wouldn't have had to replace the fuel rail pressure sensor had done it by the book to start with. I also thought I might have a fuel pump problem if that sensor didn't cure it. I've had batteries fail as new as 6 months old and I've had them last as long as 9 years. I've relearned that low battery voltage can cause weird things to occur.

Greg B

 

I almost forgot, madcowracer, if it is the fuel pump, don't mess with Autozone or Advance Auto Parts or places like that. Get an OEM from Ford or go to NAPA. It costs a little more, but everyone I know has had problems with the retail places like Auto Zone with fuel pumps. They just don't seem to last long. I hate doing the same repair like a fuel pump more than once to get it right. As ryan50hrl stated you can get a good price from one of the sponsors of this site on OEM parts. Worth the wait in my opinion.

Greg B