Fuel Pump Melted...
 

I replaced my fuel pump today because the truck died on us on the highway. The positive lead to the motor inside the pump got hot enough to melt the plastic. I'm a little worried that there was enough heat to melt plastic inside the fuel tank. I have a picture of the melted part as well as the same part of the pump I replaced it with (a pull out of a totalled Navigator). How do I post pictures? Does anybody have any idea what may have caused this to happen? Is it simply overheating due to a failing connection and low fuel or some other failing component that could make this happen again?

I would check closely for a bad connection, corrosion, faulty plug. Resistance in the circuit slowly increasing, yet not blowing the fuse. If everything is good to go it was just the pump failing. The one in Apollo 13 blew the side out. Sometimes we wonder how things work so well.

Until you have at least 25 posts you will have limited privileges here on FTE.
You need to create a photo account somewhere such as Picassa, photo bucket or the like.
Then you can link to the pics.

email the pic to me i'll post them up, 7677erick@gmail.com

i just responded to a different post - these fuel pumps are burning up now that the 07+ have aged. here is mine. I have also submitted a report to NHSTA,as that is what will eventually drive a recall.

completely melted

http://i707.photobucket.com/albums/w...s/DSC_0080.jpg

http://i707.photobucket.com/albums/w...s/DSC_0079.jpg

http://i707.photobucket.com/albums/w...s/DSC_0078.jpg

i've heard for years that you should keep your fuel tank above 1/4 tank to keep the fuel pump cool so they'll last longer. Perhaps if you'd kept your fuel tank above 3/4 tank the plastic wouldn't have melted:-X04

Seriously, this is a big cause for concern. Chafing wires in a fuel tank were also suspected in taking down that TWA 747.

How many miles when it failed and what were there any symptons before it failed?

Sorry it took me so long to respond, my second son was born three days after that post, it was a good thing I got that thing running when I did. My pump looked exactly like those pictures D-Rock posted. I took it by the dealer and they said that this is a common problem for that pump, something to do with a higher draw on the pump when it's warm outside combined with the fuel being low (1/8 of a tank) so it's not being cooled by the fluid. It felt a little like he was BSing me because I didn't take it to them to do the job and he felt I was wasting his time but I have heard about keeping the tank from getting so low and I never let my truck get under 1/4 of a tank, however my wife doesn't seem to realize there are gauges there until lights start turning on. Maybe this will get her to look at it little closer.

And it has about 81000 miles.

I suspect i have the same issue. My wife called me on her way home the other day and said "it just died". It has a 1/4 tank of gas. I have had the flu so a good friend of mine towed it to his house and said it has no gas pressure at the fuel rail..

My question is this: Does anyone know if i can replace the pump only, not the entire assembly. I have priced the entire thing anywhere from $300-450. I found on EBay you can buy the pump only for less than $100. My dilemma is that i want to buy local instead of waiting a week for this part from ebay and after spending time on the phone and internet cannot find a part that matches at the local parts house.. thanks j

Those push-on; connections are not impervious to contamination. Very poor indeed. Only thing keeping a fire from happening was fuel vapor no oxygen. I believe it is a low life build.

I'm not sure about only replacing the pump, I found an assembly from a Navigator on eBay and it's held up fine so far. Fortunately I was able to just ride my motorcycle and she took my truck everywhere until we got it fixed. It was a hassle for her with the car seats but we felt it was worth it.

Hey guys. I replaced the same part on my 05 expy at 53k ( truck died on highway and thus was towed) and again at 107k again died but this time on the road to my house just off highway and again was towed.. in 09 the part and labor was 200. at stealership and this time was 650 at the stealership and they also replaced the cable and wire plug. TROUBLED me that truck had a melted wire on the FUEL PUMP!!!! but it is running strong at 110k

ok, i just replaced the pump in mine. the pump was melted and was definately part of the problem. Now that i have replaced it im still having the same problem with no fuel pressure. I have checked fuses, relays and the inertia switch. what i have found is that i do not have voltage at the inertia switch. i do have 12 volt out of the relay terminal and the fuse in the fuse box.

im stumped at this point. does anyone have the wiring diagram for the fuel pump circuit? thanks in advance for help or suggestions

Does this help U folllow thru 2 the fuel pump module?http://www.bing.com/images/search?q=...electedIndex=4


fuel pump diagrams for expedition 2007 - Bing Images

what are the odds of there actually being a reacl for the pump?