So, you have a newer (2004-2008) Ford Expedition/F-Series pickup 5.4L V8 and you go out to start it one day and you have a crank no start condition (it just cranks and cranks and cranks, but it won’t fire). You turn into Samir from the movie Office Space momentarily. If you haven’t seen it, search “Samir Office Space Traffic” on youtube. There’s swear words in it, pretty hilariously mashed together ones at that, so there’s your warning. Okay fine, here it is, NSFW obviously:

Now, your neighbor, or buddy, or brother in-law “mechanic” tells you it seems like your fuel pump is bad. So, you have said “mechanic” install a fuel pump in your driveway for a semi-hefty fee. You turn the key, and you become Samir again because your truck still won’t start.

This was the unfortunate situation one of our customers ran into recently with his 2006 Expedition with 115,562 miles. He’d had someone put a fuel pump in the truck thinking it would fix the problem, but it didn’t. He had it towed to us and paid us to diagnose and repair the problem. This truck has been gone for over a week, but I just did a Google search to look for a part location and found that it’s a VERY common problem in newer Ford trucks.

The problem? A fuel pump driver module. This is what commands the fuel pump to engage when it’s needed. The other problem? It’s made of aluminum and mounted in a place where salt sits on the frame and corrodes the bottom side of the module, allowing moisture into the driver module, shorting it out.

Here’s where it sits on F-Series trucks:

The part is circled in red, the spare tire cable/mount is circled in blue. Drop the spare tires and you’ll see this part. Now, the side that corrodes is the part that’s touching the crossmember so you may have to remove the module (2 bolts) to see the any damage. Our Expedition’s module was near the fuel tank along the frame rail on the driver’s side.

This is what ours looked like from the top:

…and underneath:

Let me tell you, that thing smelled TERRIBLE. Similar to how the turn signal module on my Harley smelled when it self-destructed 84 miles from home…but that’s another story.

This fuel pump driver module is available through your local Ford dealership, or some parts stores have the Dorman aftermarket part available.

How do you prevent this? You can’t, really. One thing that may help is regularly washing your truck and making sure the underbody is cleaned as well. Most “Deluxe” car washes at the gas station have an underbody wash. Salt = corrosion. Car wash > salt.