I see everyone having the same problems I had with my 2003 Expd. Stalling, then cranking but not turning over. I changed my fuel pump, my battery, my fuel filter, and then I got some good info. The relay Fuse board in the Expeditions are somehow getting damp. The fuses when damp will burn up. I found a relay board and ordered a new fuel relay fuse. Luckily I knew a fellow who saudered my new fuse on and my truck started! I dont know how Ford is getting away with no recalling this fuse moisture issue. Good luck all. I hope I didn't confuse the hell out of Everyone.
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i don't see where one person is having that problem on this site(cranking but not turning over)?cranking means the starter motor is cranking the engine over! where is the relay fuse board?there is a 20 AMP fuse that powers the fuel pump relay,and it just plugs/push in, inside the fuse box under the hood on my truck and yours.no wires to solder.no circuit board? unless you are talking about the FPDM mounted next to the spare tire that goes bad due to corrosion/rust/short..or maybe you mean the GEM Module getting wet because of windshield leaking?
stevieray1, obviously you have no experience with these trucks. They don't have simple plug in relay like most common vehicles. So it's little more complicated than pulling the bad one out and popping the new one in. There are numerous issues all related around the fuel pumps and fuel pump relays on these trucks, sadly the 1st solution is to replace the fuel pump which generally has melted wiring and if it still doesn't start then you can move on to replacing the relay/fuse box board to replace the fuel pump relay.
The moisture would come naturally over time, from leaking down from the door. I wish there was a recall I am working on one now, but knowing FORD they would likely say it has too many miles on it for the repair.
I have had the same problem on my 2003 expedition several times and it's frustrating. However Ford told me they couldn't even repair them or get the relay I need to buy a whole new fuse panel which was like 1200 bucks I'm like no way so I searched relays and found a set of 5 exact ones on wish for 12 bucks. And did it myself. Just make sure to take a picture before pulling all the fuses so you know what goes were.
I have a 2003 expedition that went down on me about a month and a half ago. I ended up changing fuel pump, fuel filter, the mass airflow sensor and some other things. I also change the intake. The original problem was the car shutting off, after about five minutes or so……it turned out to be one of the vacuum hoses which was “ shrinking” I guess you can say, as the truck was running and when it fully closed, that’s when the truck with cut off. Nobody noticed that until my dad was just watching because we changed everything and couldn’t figure out what the problem was. He then saw that hose “collapsing”. however, now after about five days, it is not cranking again.
I am going to try your solution and hopefully this will fix my issue. It is just strange that after I fixed all those other things, the truck was running fine and then it just stopped running again. My dad checked and there is no fuel getting to the engine so for whatever reason the fuel pump is not coming on I guess.
stevieray1, obviously you have no experience with these trucks. They don't have simple plug in relay like most common vehicles. So it's little more complicated than pulling the bad one out and popping the new one in. There are numerous issues all related around the fuel pumps and fuel pump relays on these trucks, sadly the 1st solution is to replace the fuel pump which generally has melted wiring and if it still doesn't start then you can move on to replacing the relay/fuse box board to replace the fuel pump relay.