No fuel

I have a 2000 Ford Windstar LX 3.8 L. 170,000 miles. One day I drove it about 30 miles and turned it off. It would try to start but would not keep running. I could hear the fuel pump when I turned the ignition on, so I didn't think it was fuel. I let it set a while and it still wouldn't start. I tapped the EGR valve and it started. I assumed the EGR valve had stuck open. I drove it for a while with no problems. Then the other day it wouldn't start. The fuel pump did not make a noise. I tried to check the Fuel pump relay, but couldn't get it out. I ordered a fuel pump. I went out and turned on the key and I heard the fuel pump. It started and ran fine. I am going to replace the fuel pump anyway and likely the fuel pump relay. Does anyone have an idea about whether it may be the wiring that loses continuity, or could trying to remove the relay have restored a connection? Thanks.

Be careful of using fuel pump noise - or lack thereof - as a symptom of a bad fuel pump.

It's important to realize that - when the ignition is turned on - the fuel pump energizes for just a few moments to pressurize the fuel system. It then turns *off* until the engine is started. Find a way to verify that you don't have fuel pressure before committing to replacing the pump.

I didn't run into fuel wiring or pump relay issues, so I can't comment on those items.

That said, the fuel pump on my '00 Windstar failed - and I replaced it myself. A few thoughts:

- Old electric fuel pumps can get flaky as they fail - so working for a while, and then not working for a while isn't an entirely unusual failure mode.
- Replacing the fuel pump does indeed involve dropping the tank. The job is a fair amount of dirty, hard work - but isn't really all that complicated.
- I found that the worst part of dropping the tank was removing the fuel fill hose. The fittings and pipe behind the splash shield in the driver's side rear wheel well are prone to corrosion. I ended up cutting the fuel fill hose and replacing the hose itself, as well as the metal fuel fill pipe (mine was badly rusted).
- Removing the pump assembly and related hardware wasn't bad at all. After hearing stories about gunk at the bottom of a fuel tank, I was pleased to see that mine was pretty clean.
- Make sure you replace all of the in-tank and external fuel filters (I recall there were at least two in the tank, plus the regular in-line fuel filter).

I agree with above .... but I would certainly replace relay, and in-line filter, before dropping tank. If you end up dropping tank, buy the fuel hose fill assembly ahead of time.

Some WD-40 may help loosen relay base. Be sure to lubricate replacement relay base blades.

I took the tank and the fuel pump off several years back. I found the filter with some varnish on it. I am going to replace the pump regardless with the years and miles on it. Thanks for the idea about WD-40 to help get the relay out. It looks like the connector is trying to come up with it. I was going to make a tool with a lip on it to get between the relay and the connector to pry it out. Thanks to both of you for your responses.

I worked on the vehicle today. I got the relay out by using penetrating oil. I was able to use a jumper wire to pump gasoline into a container. I am 71 years old and when I let my head go back off the creeper, I got dizzy and didn't feel like taking the tank off today, but I put in the new relay and it seems to be doing fine. I will replace the fuel pump later. Thanks for all the information.

All that experience! Hopefully you won't have to drop the tank again, cause if ain't no fun at all! If I even have to drop my tank again, I may finally make a trap-door through the floor pan. I believed I've dropped it four times at least ... cause once the new replacement pump assembly was bad out of the box! Its been a while since I last dropped it. Got my fingers crossed. 453K miles and counting.

Watch those dizzies! Drink some beet juice daily and get some exercise ... 15 or 20 minutes daily. BTW, I've got you by seven years ... and every day is a gift for which I am grateful! Good luck to you!

All that experience! Hopefully you won't have to drop the tank again, cause if ain't no fun at all! If I even have to drop my tank again, I may finally make a trap-door through the floor pan. I believed I've dropped it four times at least ... cause once the new replacement pump assembly was bad out of the box! Its been a while since I last dropped it. Got my fingers crossed. 453K miles and counting.

Watch those dizzies! Drink some beet juice daily and get some exercise ... 15 or 20 minutes daily. BTW, I've got you by seven years ... and every day is a gift for which I am grateful! Good luck to you!

Thank you. I don't guess I have ever drunk beet juice. I have eaten pickled beets. I do try to get some exercise. My Windstar is a second vehicle now. I don't drive it so much. It has been a good one. It is interesting you have gotten 453K on yours.

Of course fresher is better on the beets. The experts say clean the roots, blanch in boiling water to kill of the little bad-things ... and then process in blender. Too much effort and mess for me! So I do the thing that is a distant "second best". ... quarts of cold-pressed juice from Walmart (when I can find it). If you consume a glass full daily, its supposed to drop the blood pressure 5 points or better. I believe it works. .

... but then, I'm gullible.

I don't think I have ever seen beet juice at the Walmarts here. Anyway, my blood pressure is fine. I think I have some inner ear problems that cause me to be dizzy when I lean my head back. I guess as long as the beet juice works for you, that is sufficient. Thanks again for your suggestions.

FYI, I just had a fuel issue...
Vehicle stopped running, no fuel pressure, but had a 1/4 tank of gas. I could hear the pump running at key on. I also checked for fuel flow at fuel filter input.

I put 2 gallons of gas in and it started. I filled the tank and in total put 23 gallons into a 20 gallon tank. The gauge read only 1/2 a tank right after adding the fuel. The problem was the anti-slosh module in the back of the instrument gauges module.

It had a bad anti-slosh module.

That is not my problem. There was fuel in the tank. That is something to be aware of though. Thanks.

Imagine what can happen if there is a bit of debris washing around the tank. As the fuel is consumed, and the fuel volume drops, the debris may gather against the pump inlet strainer; blocking the pump inlet flow. As new fuel is added to the tank, the debris is apt to be washed away from the pump, now swirling about in the larger fuel volume. The cycle repeats as the fuel get low again.

I'm pretty sure I have observed this happening perhaps three times in different vehicles. Nothing is really cured until the tank is opened up and the debris removed, or inlet strainer replaced.