Last post on Apr 16, 2013 at 8:59 PM
You are in the Ford Expedition
What is this discussion about?
Ford Expedition, Engine, SUV
#35 of 48 Re: 2003 ford expedition [ssherd]
Sep 10, 2012 (4:23 am)
Coils and plugs maybe?
#36 of 48 Re: My 2003 Expedition dies randomly also.. [fnoel]
Sep 10, 2012 (8:33 am)
My 2003 5.4 Expedition Eddie Bauer was losing power and stalling intermittently for about a year. Same kind of issue as described here on this thread, stalling and restarting almost right away. It would be fine for a couple months and then stall out frequently, then it would be ok for awhile. No codes, no check engine light.
I replaced the battery cable so many have mentioned which was rubbing on the AC pipe. The replacement cable from the dealer has a braided anti-chafe cable so that is a good part to replace regardless.. I also had the PCM programed by the dealer and yet it kept stalling.
This month it started to stall on a much more regular basis and I was able to get it to happen on my mechanic's watch. He had a fuel pressure gauge hooked up and it was losing pressure at stall. He figured it was the pressure regulator or part of the entire fuel pump assembly. There is no fuel pump control module as in newer models, the PCM controls the fuel pump from what I understand. So he replaced the fuel pump assembly in the fuel tank., but the next day it hesitated at highway speeds twice and then stalled out at low speeds twice. uhg!
Upon looking into the fuel issue more I came across these two threads...one with a complete no-run and one with an intermittent.
http://www.ford-trucks.com/forums/1149113-help-fuse-box-replacement-2003-eddie-b- - auer-expedition.html
Both authors describe a bad fuse box design, either from a windshield seal allowing moisture into the box or a bad circuit board design. I ordered an OEM fuse box from here:
http://www.autopartscheaper.com/2003-Ford-Expedition-Fuse-Central-Junction-Box-j- - un-p/3l1z-14a068-aa.htm
They had it in stock and $60 less than dealer price. The part came in a Ford Factory sealed box with all new fuses and relays installed. Installation took less than 30 minutes. I didn't take the time to disassemble the box to get to the relay. I'm guessing though that since I have yet to have the truck stall again and have replaced every other part in the fuel system I finally have found the issue. My mechanic did believe that the fuel pump assembly may have been the root cause of the relay overheating. Saying that if it was drawing too many amps and the relay was soldered on it could have been the reason for it to lose connectivity. I guess that plausible. I would have the amperage draw tested before replacing the fuse box just to ensure the fuel pump assembly is OK and that you don't blow another $300 fuse box.
#37 of 48 Re: My 2003 Expedition dies randomly also.. [parriojas]
Sep 15, 2012 (4:03 pm)
I was having the same problem with my truck. I recently changed out the fuel pump relay and changed the fuel filter. So far the truck hasn't cutoff.
#39 of 48 Re: My 2004 Expedition dies randomly also.. [tonychef]
Sep 22, 2012 (1:48 pm)
I found the wire that was causing the engine to stall at low & high speed, taped it good with electrical tape, made sure no electrical wiring(s) are touching the aluminum freon pipes but my Expedition continue to stall. I hooked up my scanner to check my I/M monitors, I have no check engine light, & my evap system is "incomplete" (rest are "OK"). Also I noticed my idle speed is slightly low between 750-800 rpm at start up & down 700 rpm at warm temp. So I took off the air intake assembly & did a visual check. I found the fuel vapor separator tube (hose) is deteriorated, Ford Motorcraft part #9D289, that connect to the vapor canister purge valve part #9C915. It's dealer only item & would you believe it cost $57.18? http://www.fordparts.com/Default.aspx Cleaned the throttle & intake & sensor connectors with CRC spray cleaners. Then I went to Pep Boys & got me a 3/8" I.D. X 2' of fuel line hose for $4.49 plus tax to replace the fuel vapor separator hose. My rpm now is around 1K rpm at start up and around 800 rpm at operating temp. Drove it around the neighborhood, no problem. It's idling fine.......Test drive at high speed (freeway) in an hour. Wish me luck.
#40 of 48 Re: My 2004 Expedition dies randomly also.. [amboytex]
Sep 23, 2012 (6:09 pm)
Found this video on You Tube video, hope it help you find that fuel vapor hose.
Mine is fixed. I did visual & wiggle tests, got lucky & saved a lot on expensive suspect defective sensors & parts. I did replaced my in-line fuel filter but that's overdue. Other than that, I spent $4.49 for the temporary fuel line hose but ordered the oem Ford 9D289 fuel separator hose & for 2 cans of CRC Throttle Body & Electrical Parts/Connector Cleaners.
#41 of 48 Re: My 2003 Expedition dies randomly also.. [tonychef]
Oct 13, 2012 (4:24 pm)
I read your post but I am having a hard time finding the wires. I was hoping you knew the names of those wires so I can you tube or google it and see how I am able to fix my car. I am having the same exact problems you were having. I to have a 2003 Ford Expedition. Thank you!!
#42 of 48 2004 Expedition dies randomly
Oct 28, 2012 (7:16 pm)
I had the same problem. Replaced the fuel filter, fuel pump, took it in for repeated diagnostic. Of course it never dies while at the dealer or my regular mechanic. It finally dies and would not re start. I had the dealer test for power all the way back to the fuel pump. Turned out it was the fuel pump relay. Had to replace the whole interior fuse panel.
Just glad it finally got figured out
#43 of 48 Found it! 2003 Expedition used to stall every few weeks while driving
Feb 03, 2013 (8:12 pm)
The guys at the dealership couldn't find the cause for this issue.
Said I have to start the elimination process by changing the fuel pump and some other stuff quoted at around $1500 total.
Didn't do it.
Last week it died again and I couldn't start it.
Had it towed to PepBoys in Thousand Oaks CA .
The guys their spend almost two days to diagnose what is the real problem.
Eventually they said it is most likely the interior fuse panel.
They got a new one - and the car works great.
Cost: $415 for an original Ford fuse box
Installation and diagnostic: $250
Very happy with Pep boys!