97 Windstar- Fuel pump/filter/something!?

Ok, so the other day we went on a long trip (long for us) of about 110 miles for the round trip. After coming home and letting the van sit for about 3 hours it would not start. I checked all of the fuses on the block and all of the ones in the CCRM and they all checked out fine. No fuel smell, and it was definitely getting spark.

Just for the heck of it, I hit it with starting fluid while cranking and it fired up and ran until it dissipated. Got underneath it and hit it with a mallet about the fuel tank area and it started right up (with wife turning key of course). Ran great and started back up a few hours later. Once it sat overnight, it wouldn't start without hitting the fuel tank in the same area, but it WILL drive wherever I need to go without any exceptions (rough idle, stalling, etc.-NOTHING).

Fast forward a week and it will only start with a hammer tap to the tank, even if vehicle is shut off and immediately re-started. Common sense would tell me that it is the fuel pump, but would the pump allow the van to run and drive fun once started, but not start without some help?

I apologize, I should have mentioned that when I attempt to start it in the morning, that it will fire right up for about 2 seconds, long enough for the tachometer to jump to about 1200 or 1500, only to follow a steady decline to stalling, where hitting the gas pedal makes no difference at all. Then it goes to the aforementioned no-start-unless using a hammer on gas tank-condition. LOL.

I have a 2000 model so not sure if it's much different or not. Do you hear the fuel pump run for a couple seconds and then cut off when you turn the ignition switch to "on" but not far enough to crank the engine? Have your fans, radio, accessories all off for silence reasons at this point. You should hear a high frequency "whurrr" sound for a short time as the fuel pump spins to pressurize the line. If you don't hear that, I would guess on the fuel pump going out. Running a car's fuel tank to near empty especially in the summer really shortens the life of a pump as the gasoline acts as a cooling agent to keep the pump cool. I used to never fill up until on empty (idiot light coming on) until I found this out. Now I fuel up at > 1/4 tank esp. in the hot summer months.

There is also a fuel relay and fuel relay reset switch in the circuit that could be causing a problem but since you "cure" the problem by banging on the fuel tank (and thus the internally mtd. pump), it sounds like that is your leading candidate. GLTY - post back with more info, someone here will have some better suggestions probably to help you.

Well it certainly IS easier to start with more than 1/2 a tank of fuel now. When there is more fuel in it sometimes it will restart after the initial bang on the fuel tank in the morning.

I do not hear it whirr or hum while I lay next to the tank and have someone else turn the key to the ON position, but after a few well placed thumps with a mallet, sometimes I can hear the buzzing/whirring noise just briefly, followed by a start.

Is the pump in the middle of the tank on this van? I am just kind of curious what area to focus on when I do thump or listen. I guess I kinda wanted to know if this could be the strainer or a loose connection somewhere inside the tank.....

Working on the fuel tank and/or the internally mounted fuel pump is above my pay grade. I've never attempted any type of DIY involving this area so can't really give you any pointers. I looked at autozone.com for the repair info they have online for your vehicle and they have some drawings and pics of the fuel tank / pump area. You may want to view that site if you are interested in tackling this yourself.

I've read other posts that talk about measuring your fuel line pressure at a point by the injectors where you screw in a mechanical gauge to see the rail line pressure. This would verify that the pressure is not correct but would not pinpoint the cause. glty.

The folks who have mentioned the bumping the fuel tank to get the fuel pump to run have reported solving their problem by replacing the fuel pump.

Replacing the fuel pump involves removing the fuel tank......the pump is mounted into the top of it.......
I would get a replacement pump that includes a new "sock" filter on the pickup of the fuel pump assembly.

Please be VERY careful......the less fuel in the tank....the easier the job....but it just takes a small spark to ignite the fumes.......
I would disconnect the battery before starting the job....and be careful not to make any spark......metal tooling can generate a spark.

I would also replace the inline fuel filter.

My own opinion......If I would be dropping the tank.....I would have a replacement fuel pump assembly to install.

I can hear my fuel pump come on from the driver's seat with the door and windows closed, should he really need to put his ear on the tank?

The act of "fueling-up" can stir the tanks contents ... and do a little "washing" on the pump inlet screen/sock. That's why sometimes our problems "go away" for a while after we fill up.

If you find yourself with these symptoms, you might as well plan on dropping the tank. Not an easy task ... you can never get the tank empty enough ... there is no room ... etc, etc.

I think there's some gunk in my tank. Every time I let it get to low it starts to stall.

I think the fuel pump is the only thing I haven't replaced so it's probably just waiting for the most inconvenient moment to fail.

well now its completely dead. no hammer blows are gonna make it start now. new pump from e-bay for 35 bucks with free shipping is en-route.

Where are you now with the fuel pump replacement? I am surprised your van's fuel pump lasted over 230K. I replaced mine at 135k as a preventive measure.

How about your radiator, is it still original?

I completed the replacement 2 Fridays ago and it wasn't half bad (with the exception of getting the fuel neck to align with that hole when raising the tank :crying:)

I broke both of the new fuel line retaining clips :rofl: but the old ones were still in usable condition. I still can't get over the fact that I paid 34 bucks for a NEW pump. Some power seller on eBay (radiatordealz I think) :naughty:

As far as the radiator goes, I'm not really sure if it is original, but there is some gunk build-up from a leaky head gasket and I need to get one of those radiator flush home-kits SOON!!