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2004 Expedition Fuel Pump Relay (Non Serviceable) FIXED

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Old Apr 17, 2025 | 11:06 PM
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Jus4fun
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Exclamation 2004 Expedition Fuel Pump Relay (Non Serviceable) FIXED

So... Just giving an update on the "Non Serviceable" Fuel Pump Relay. It CAN be done. This is how:
*** I did it. And it worked. ****
1. Disconnect the battery... duh
2. Disconnect all connections attached to the fuse box (located on passenger side to the right under the glove box)
3. There are 3 bolts holding it in place. One is attached to the positive battery cable wire. (took me 2 days because of the angle and small space)
4. Remove ALL fuses and relays. (Good time to test each one)
5. Use flat head to pry the tabs holding the fuse panel to the circuit board.
6. Be careful not the bend any of the little connection things when you have them apart. Some of them will come out. But they can be put back in place when ready to put it back together.
7. If your fuel pump relay is damaged... you will clearly be able to tell. One of the solider points holding it to the board will be blown out and a light haze of brown can be seen in that area.
8. You will have to use some desolider wire (Braided copper) - I made some from a piece of speaker wire. You should probably do some more research and watch a video on how this is done.
9. When you desolider all 4 points of contact take out the old relay and solider the new relay in its place. ((Use Flux))
10. Someone sent me a link in my original post that I used to order the replacement relay on Amazon.
11. Put every thing back together ... all little pieces that fell out... snap the circuit board back to the fuse panel ... put all fuses and all relays back.... connect all connections (12, I think) and don't forget the screws. **** VERY important... make sure all connections are in tact***
12. Push the fuel pump reset button located in the back driver side panel compartment.

If you did this correctly... It will have saved you $350 to $450 (the cost of a new fuse box) + labor

Good Luck!



 
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