I watched the video and then searched for the relay. I found one on ebay and bought it for $12 + shipping. I made my own video and showed that the relay can be replaced. My daughters 2003 Expedition had all the same symptoms and after replacing the relay the car was fixed. You have to know how to solder in order to do this. Thanks for your video, it got me started
@@dudethman1000 I think that is a better solution. Wiring the relay does 2 things. 1. lets you replace it if it burns out again 2. The external relay has a higher current capacity.
I took mine apart and there was no indication of burnt relay or any hot spots around that relay at all , but shuts off while driving . I changed the fuel pump and fuel filter and still nothing
Thank you for this heads up, my 2003 F-250 had the same symptoms, 5.4L gas engine!!! 3 fuel pump replacements and finally no start at all. Service Manager from Ford dealer said there was nothing wrong with the fuse box. Ordered a replacement on ebay for $100 plugged everything in and the truck runs like a champ again. Only about an hour job, thank you again!!! You were right on!!!!
OMG! Thank you soooo much!!! I have been dealing with this issue for over a year now where my truck would just shut off for no reason. Sometimes it would start right back up , sometimes not. It would go a few months or more without a problem then one morning, nothing. Was told by a good friend, mechanic for 25 years, that it was probably the fuel pump, which I had already thought . Came across this video while trying to locate R303 location as a last resort and bam, here we go. Just pulled fuse box out and there you have it, middle relay burned in the same location, plus white smoke dust. Once I had the board in my hands, you could really small the burnt electrical. About to order new one now. Thanks!!!!!!!!!
You are a life saver. I just had this happen to my 2003 Ford Expedition and I changed the fuel filter then the pump thinking I solved the issue. I was driving down the highway and again car just shuts off and would not restart until the next morning. I saw your video and went to the junkyard and got a fuse junction box and installed it, and sure enough my previous fuse was burned on the corner just like yours. Thanks so much for this video!!!
Thanks for posting this video. I have a 2004 Expedition 5.4L that was experiencing random stalling with no codes. When I removed the fuse box, I found that the relay that controls the fuel pump was slightly burned just as described. Replaced the fuse box and the problem was corrected.
You can change the relay for ~$15 if you have any soldering skills. If not, remove the board and find someone who does. Just need an iron and a solder sucker device. Thanks for all of the other pertinent and helpful information. It helped me complete this in the dark at my work parking lot. Also, caution about those tabs. they need to be orientated the correct way else the plug in relays won't fit properly. Just be sure to do a quick plug in test for alignment prior reassemble.
Thats exactly what i did to mines no need for anew one just replace the relay and its good its been over 5 years and still kicking! Just replace the relay they are easy to find.
@@spiritualak5147 it is a relay inside the fuse box you can not see if if you don’t open the fuse box it will have a row of relays but one is for the fuel pump, i dont know why ford would design it like that i think this just stupid and for the have consumer waste $500.00 on anew fuse box when it can be fix simply.
@@spiritualak5147 i found the relay on ebay just get the part number of the it and order, i know i have a working spare fuse box , im looking for it as i write.
@@spiritualak5147 ok i found it and there is a row of small relays but they are under the surface and is the middle square relay original part number is F8VF-BA and you can replace it with F4FL-AA relay they do same function and is omron brand too. Remember is the very middle one that is fuel pump relay hope this help , like i said i have spare one let me know if anything
Great tutorial, I am having the same problem with my 03 Expedition and at first we thought it was the fuel pump. After a week of driving with the new fuel pump, the problem came back. I will definitely be doing this to fix this issue once and for all.
!!!!!!!!!!!!!!!!!!!!!!!!! I hope this got someone's attention if you're getting ready to do this job. IF THE GROUND WIRE CONNECTED TO THE FUSE BOX IS STILL GOOD (WHICH IT PROBABLY WILL BE), YOU DO NOT HAVE TO RUN THE NEW CABLE THROUGH THE FIREWALL. YOU CAN JUST USE THE OLD ONE. There's a cover over the ground wire on the fuse box. Remove the cover and a bolt will be exposed (10mm bolt i believe). Unscrew that and the fuse box will be free from the ground wire. This will save you SO much time and headache. The cover is a little annoying to get off, but I just used a small flat head screw driver and lifted it up on each side. This is an easy fix. You may have to use a very little bit of muscle when removing the panel that's stuck underneath the door guard rubber. Very easy fix though. Great vid by the way
Hello Alex! thanks for this helpful video. I've had my fuel pump and relay replaced along with many other things. Now the mechanic is saying it's the fuse box. My '03 expedition keeps cutting off. Sometimes it will start right back up, and other times as you said it can take up to an hour. I was getting so frustrated to the point of selling it, but I feel this could be the underlying issue. My husband and I will try this, but this will be the last ford I purchase. Too many problems that don't show up until you have spent hundreds of dollars on things that probably weren't even an issue.
Alex, Thanks for video on replacing the 2003 Ford Expedition Fuse Box assembly. I had exactly this problem with the fuel pump relay. It overheated and melted the solder joint on one of the circuit board pins so that it would randomly stop powering the fuel pump. I took it a step further and replaced the relay on the circuit board. Put it all back together and all seems fine. The replacement relay is available from Digi-Key (800 344-4539) for around $4.25. Part Number Z2696-ND (mfg p/n G8Qn-1C4 DC12 Omron Electronics). Thanks again. You saved me about $350 dollars for a new fuse box.
Alex S Good video, thanks for sharing. This water leak and fuse box damage seems to be an issue with the Expeditions over several years! As far as repairing the fuse box, it's not something the average person can or should do as you could do more damage to the circuit board, but you could always order the new relay and take the parts to a local electronics repair shop and have them do it for you. They shouldn't charge you more than $20 to fix it.
Is this relay interchangeable? I had a PCM Relay go out in my 2003 Navigator and wondering if this same fix would be possible? I'd love to not have to spend $350 on a new fuse box.
I have solved this same problem by simply unsoldering and replacing the fuel pump relay on the PCB. This avoids the replacement expense of the whole PCB assembly. Such relays are found online at very low cost.
My .02, it is the fuse box. there is a manufacturer defect in the vehicle itself with water/moisture intrusion. The moisture gets on the card/box and wreaks havoc on the electrical components. It's a subtle process, but when it hits it will leave you stranded like a big dog. I also asked for a dealer quote and got a price of $800 to remove and replace. The brand new part at the dealer is between $450 - $600. Used are $150. The used are like trying to find a decent politician, nearly impossible. The used do exist, but you will be on the hunt on your phone for a minute. I LOVE my truck, but this is the only issue I have ever had with it. Too bad it is a huge problem when it hits. Best of luck to all my fellow Triton Expedition owners.
Hi Alex, in the behalf of my family I would like to thank you for the video you post on youtube. that solve my problem in the first try, that was awesome Alex thank you and GOD bless you. :-)
I have a similar problem with mine but with battery saver relay (304). Thank you for this video, I didn't want to break anything so this helped me take mine off flawless.
03 expedition had the same stalling issue, no crank, no power to starter, half the electrical worked. Bought a replacement relay and desolder the burnt one and solder the new one (done by a specialist ) and that did not fix the problem. Bought a used fuse box $65 ebay of a 04 navigator wrecked covered in snow the seller assured me it was interchangeable with expy and in working condition. Installed it my self 15-20 min and started right up haven't had one stalling issue since and all electrical is working 100%. Do it yourself really easy. Dealer $350 for fuse box and $500 for 20 min labor job wonder what they do the other 4 hours?
@Alex S, thank you so much for posting and sharing this information. @Rich V, thank you for sharing the replacement Relay supplier’s name, phone number, and price. I called Digi-Key Electronics (800-344-4539) and ordered the relay. Now, the particular part # you ordered is out-of-stock so I ordered the cross reference, Panasonic P/N JJM1-12V (Digi-Key P/N 255-2220-ND) at $3.55 + shipping. I actually already bought and had my mechanic install yesterday a brand new Fuse Box Assembly on my 2004 Ford Expedition E.B. with 245K miles, but I’m still replacing the burnt Fuel Pump Relay on old Fuse Box Assembly as a back-up or if anyone is interested to buy the reconditioned Fuse Box Assembly. @Alex S is 100% correct because the damaged relay is exactly where he said it is!👍🏻 My Expedition was experiencing the same exact symptom: sudden engine shut off while operating the vehicle; no engine light nor codes whatsoever. It first happened some 18 months ago, and it happened like 3 times (the last time was only this June 14, 2020). And, just like many, I brought it to the dealer and they can’t find anything, not even a clue! After reading this post by @Alex S and before I had the new Fuse Box Assembly installed, I called and was told by the dealer it would cost $891++ to replace the Fuse Box. Good luck people!
You can buy relay's on the parts stores 2 for $12.oo and un soder the old one and replace the relay with a new one put it back together and put it back in the truck it will run like a new truck . Take the hot post of the battery before you start the take a jumper cable on the disconnect hot cable and put the other end one the still connected ground cable do not let the hot cable touch the hot post on the battery wrap it with a rag and keep it away from the hot post so it doesn't ark on the post .when you do that for about 30 minutes it will clear all the bad codes and when you put the fuse box back in re connected the hot cable back on the battery and then restart the truck and go through the restart drive very slow and not fast it will reprogram your truck and it will drive like it new .you will save hundreds of dollars. Look on Amazon for your new relays thank you for your video
Great vid, What's the exact vehicle for this video your doing . I have a 2003 Ford expedition Eddie Bauer 5.4L 4WD. If you don't mind me asking ,What's your vehicle that this fuse box came from . Thanks
I resoldered the connection and haven't had a problem in two months. What happens is the relay get to hot from possibly a bad fuel pump causing to much resistance and overheats the connection and de solders it. Re solder it and clean the relay! You do have to remove the relay cover.
I went through the same exact problem, but i was able to find one at a truck salvage yard. Great Video BTW. My question is. I have my old one now & if this problem happens again in the future is there a way a could solder one of the other 5 relays to replace the burned out one? Is all the other relays the same? I was hoping that i could solder 1 of the other relays from my old fuse box into my other one if it is posible? Any help on that would be Greatly appreciated. I own it & woud love to keep it, so in the future maybe this could be possible? Thanks for any help. Again Great Video!
Same problem 04 EB 5.4L expedition-- Ford quoted $1600 to replace pump and fuse box.. I intend to replace the box, but should I replace pump too? They said both were bad...
i need help i have a 97 expedition and its cranks but wont start i live in san diego. i have had the shift interlock selenoid replaced because it wouldnt go into gear and the and the some other things its now the original key to the car but i never had a problem with it though and the theft light is blinking
Alex, nice job.. I have a question... If the fuse box is completely unplugged as if just changed, do i need to have the PCM reset/flashed or whatever they say they need to do at the dealership? Or can i just plug and play? I thought I would at least disconnect battery and cross + and - for 10 min to completely drain memory and hopefully reset and get rid of my problem. My problem is that i had a drain on battery (9.49) on volt mter... I only disconnected fuse box to eliminate all circuits. It did not and now dash says all doors are ajar and can't get it out of park. all i did was to unplug fuse box. Any suggestions? Thanks, Frustrated with Ford
I think I may be headed toward this failure in my 2003. The engine will stumble or stall out completely at highway speeds. I coast on to the shoulder and it cranks right back up. It used to happen once or twice a month but last week it happened 3 times in one day. No rhyme or reason, No engine light or other electrical issues. I heard something about the alternator wire chaffing and shorting out on the AC piping on some Expeditions but im not sure if that's what I'm dealing with
thank u i thought mines was the fuel pump. Same issue as yours. Now my truck won't start and saying low oil pressure. I did this step and mines burnt. Ordered the part and hopefully this will fix the problem.
Hi I have a question I hope somebody can answer. I have the same problem but with a 2004 expedition. I was told to replace the fuse box. But would it make sense to buy a fuse box from a year not affected by this problem or should a buy a fuse box from the same year?
The relay that is replaceable on these are some times loose and it will make the vehicle die replace the relay and good for a while so took out fuse box soldered the back side on the plate where the relay goes and thank full to GOD it has been good for over 2 yrs!
I have the same problem with my 04 Lincoln navigation change fuelpump still happens changed a fuse it was fine for a wale did again so kinda thnking of do what u did maybe jest to check if the board is damaged sinces it out y not replace well the point is do thnk could have the same problem would like feed back thnk u.
My check engine light has also come back on. I understand now why fords are ( found on the road dead). The ford dealership couldn't even diagnose it as the fuse box until I had my breakbooster, fuel pump, fuel relay, a tune-up and a host of other things.It was the last code to show up. Maybe I needed some of those things anyway, but I'm almost certain that this is my main issue of stalling out.
Pcm relay@kevin warren. I have an 03 expedition manufactured in jan 03. Early model year expedition/navigators have a different relay/module control units vs units manufactured later in the year. It is a very common problem with early 2003 expedition. Every few months I would insert the key and would be greeted by a loud buzzing noise coming from the relay box by the passenger kick panel. I purchased several little relays and kept them in the glove box. Eventually the box started to burn and the replacing the modules no longer worked. The box is relatively easy to replace if you mechanically comfortable but a novice can do it as well. The biggest challenge is running the plug thru the firewall to the computer. THE FUSE BOX ISSUE IS DIFFERENT FROM THE RELAY /MODULE CONTROL BOX ISSUE
Ok thanks! This issue started over 4 years ago and changed 3 relays in those 4 years. In the past 6 months I've changed 3 counting today so it sounds like it's on its way to completely going out.
Update: So my husband and I went to a local pull-apart which has junked cars. They had one '03 which thankfully still had the fusebox. We removed it, and just put it on without changing any of the fuses. My truck fired right up!! hasn't cut off since. I'm praying that it doesn't. The mechanic told us that we would have to buy a new one from ford which would cost us around $700. We paid $30
+Aaron Wilson When we got the used one I told my husband to put it on as is. We didn't remove those fuses or anything. We just connected it back to the ground wire, and screwed it back against the panel. It works just fine, but of course I kept my old box with fuses. I really hope you get your truck fixed. This video was a lifesaver, because I didn't really know what was causing the truck to cut off. If you can find another fuse box cheap I would advise putting the used one on first. It only takes about 15 minutes before you go through changing all those fuses.
+William Leggett William my 2204 Expedition does that , I found the problem was the Combined coil and spark plug assembly. Just do a diagnostics to find out which one of the 8 cylinders is doing it and replace it , its easy to do , cost was about 40 bucks.
Townman1, these are two seperate problems. Coil over plugs do not cause the engine to randomly and entirely shut down. When the coils fail, engine still runs, unless all coils fail at the same time - highly unlikely.
He'll I have a expedition 2003 I recently replace the battery and the alternator but after running it half an hour to an hour it just dies completely and drain the battery out can this be fuse box problem??? pls help
My expedition is a 2004 and I am having a problem where i have no power to the dash or interior Accessories. I installed led brake lights and i went to turn the ignition on and i heard a pop and saw smoke. Now after replacing the starting it starts up but it still doesnt have power to the inside. Is this a sign to a blown fuse box
I would have unsoldered the burnt relay and switched it with another relay that is less important if it failed then try and find a substitute relay. Auto makers build planned obsolescence into their products to make a good profit on the upkeep of their products.
Another cheaper fix than putting the OEM fuse box back in, is to cut the wires leading to the fusebox and then buy a $5 relay and solder those same wires back onto that relay. Works perfectly...Also caution on buying "used" fuse boxes on the internet - you have no idea how many miles (running hours) are on the used box, so you could set yourself up for failure again if you get an old one. You don't need to unsolder the old burnt relay, because you are taking it out of the program buy cutting the jumpers that are going to the relay in the first place. Most folks are not technical enough to unsolder parts off of a circuit board, and you may damage the board by attempting the suggestion above. Better to cut the wires, and re-attach to new $5 buck relay. Instructions for such are on the web.
Additional information from further up above remarks, this particular problem is annunciated, so there are no codes. Other problems such as COP, or spark plug issues are annunciated on the code computer.
from: www.ford-trucks.com/forums/1183363-5-4l-super-duty-stalls-randomly.html wire diagram is found on the above page too. I have dealt with this for a couple of years now. I changed multiple components including fuel pump to avoid purchasing the $600.00 fuse block that has the fuel pump relay built into it. I screwed around with this for too long not to share this helpful hint First Let me help you determine if your problem is the relay. remove the passengers side kick panel. behind it you will see the inertia fuel shutoff switch. It has a reset button on top of it and has a plug on the bottom of it with a green and yellow wire on one side and a purple or pink and black on the other. hook a test light onto the green and yellow wire. start the truck. Drive or what ever. you need to watch the light to see if it goes out just before the truck dies. * If the light goes out just before it dies it is your fuel pump relay. * If the truck dies and then the light goes out after it dies then most likely computer (PCM) * If the truck dies and you have ---------- where the odometer mileage reading is likely computer (PCM) Second Cheep Fix to fix fuel pump relay. Simply cut the green and yellow wire. (RED MARK ON ATTACHMENT) Then on the inertia fuel shutoff switch side of the wire hook up a new $5.00 relay. Be sure the relay powers up when your key is in the start and run position. ************************ So I want to wire the relay up I'm just not quite sure how... What side of relay do I put the green and yellow to ? And then just cap the other side of the green and yellow off? Also can I pull power to the relay from the orange and black wire from the inertia switch as well? ************************* Looking at the bottom of a relay you will see numbers for each terminal. #30 will go to your battery with a fuse in line. (Constant power) #87 will go to the inertia fuel shutoff switch the DG/YE wire #85 will go to ground #86 will go to the fuse block or any power wire that when your key is in the start and/or run position it has power. This is important. If you hook it to a constant 12 volts your fuel pump will run constantly. Yes the other wire gets caped off I hope this thread has been helping people ******************************************
WHAT? got your attention. I bought a used box with fuses from a guy, i took the old one out and PUT THE NEW ONE IN. NOW THE DASH SAY "CHECK CHARGING SYSTEM" Next thing i know my alternator dies 6 days later. Suggestions??
what are the odds of this happening again? I have a grandbaby on the way in August and don't wanna have my expedition down and not be able to get to the hospital. I have also heard horror stories of someone changing theirs out and their truck burnt to the ground that night while they were sleeping!
Also, let me add Thak you Alex S, your video is much appreciated by us all, whether we needed to know what was wrong, or needed somewhere to get started. You helped accomplish that!
What a GREAT video. I was able to fix mine, wiring in a separate relay. www.pirate4x4.com/forum/ford/1696970-need-help-mcgyvering-ford-fuel-pump-relay-04-expedition.html Mine was kinda easy to figure out, when I got to the fuse block assembly, I could smell burnt electrical. Because of your awesome video I still went ahead and took it apart with confidence. Found exactly what you found. Yeah I could have replaced the fuse block, or replaced the relay, but 7pm on a sunday night, I justed wired a new one in. Thanks again for a great video. Bradley
ive blown 50 stsrter relay fuses in 3 months freak. 700 dollars in relay fuses. some1 plz help. i cant figure out why randomly popping relays. and we need our vehicle working . down to bout 5 fuses left then broke. i have no idea what could be causing this shit. it randomly pops the fuse while driving. now its loose where they go in from changing it so many times sometimes i have to wiggle it
so far I have replaced the fuel pump and the positive battery cable and it still died out whenever... lately is died and would not start at all had it towed to fritz ford riverside where all the other work was done and they came to the conclusion it was the fuel relay in the fuse box wanted over 800 bucks I said hell no due to the fact I already paid out that much in other repairs they said would fix it and did not.. I will pick it up to tomorrow paying for all the part 400 + and see what happens .. better be fixed or else the Ford Corp is going to have a crazy woman on their hands as well as the dealership and I will blow their shop up on yelp and any other social media I can... peace out wish me luck
Just curious...but...why didn't you just solder on a new Relay...would've cost like $10.00...besides going to a junkyard and getting a used one for cheap?
Or you can buy a $20 relay instead of the $300 fuse box, desolder the burned one and solder in the new one. It's not too hard to do if you know your way around a soldering iron. :)
+JIM Koritzer one questen please have you any idea how i can fix my ford mondeo mk3 2002yr 20 tdci i have fault code 1631 somthing with bad relay of CMU but that hapend after bad glow plugs, my fuse of glowplug is out and car stop working ,i have change new glowplugs and new fuse now is ok but i cant start my car anymore becouse of that fault code 1631 and cant delete MY QUESTEN IS HOW I CAN BRING PLUS AND MINUS DIREKT ON RELAY TO TRY DELETE THAT ISSUE BECOUSE SOME ELEKTRIKER SAYS TRY TO BRING PLUS AND MINUS DIREKTLY ,BUT HOW?? THANK YOU M8
ua-cam.com/video/U6Nd65lAZU8/v-deo.html Check components and maybe your pump is the issue. The fuel driver control module could be an issue that burns the soldering in the fuse box/junction box.
i have a different problem, but i think you might be the person to help me...long story short - electrical gremlins so i want to take the fusebox out and check it... i TRIED taking out the fusebox - there is one screw on the door side, but i can't see what the heck is holding it in place on the inside closest to the motor. there is the black cable coming through the firewall, (would be great to get a close up of that - if your eyes can see if, your hands can 'feel' it), is there anything ELSE holding it in?another screw at the back or something? thanks
lcheffin same as mine... i don't know how these big burly guys manage this stuff - i'm a small woman and i practically had to grease myself like a long distance swimmer to get under there!! but the cover comes off - it's just weird when you have to let your fingers FEEL that it looks like... but look at the fuse box on other vids out of the car and you can sort of see what it should look like
The lie is that if one of the five relays go bad that it can't be repaired and that the part can't be purchased! That's a flat out lie, These relays are available and the circuit board can be repaired by a dummy much lest a human! if you don't know what you are talking about, just keep your mouth closed and stop forcing people to spend money on a new circuit board or get rid of their vehicle. Do your research first!
OK video, BUT....why in a world, you did not replace that one relay, in a middle for fuel pump??? After all this work, piece of cake, new relay in ebay, cost $8-12 only, and just unsolder old one, which in made in China??/, Ford uses cheap, underrated relays, new ones are better, made in Korea!!! Nothing else is wrong with this fuse box!!! And , no, you don't have to replace, or take out cable going to battery, just open the nut in fusebox, leave the cable there, nothing wrong with cable, clean connections sure!!! So there,...you save $400....;o)
I watched the video and then searched for the relay. I found one on ebay and bought it for $12 + shipping. I made my own video and showed that the relay can be replaced. My daughters 2003 Expedition had all the same symptoms and after replacing the relay the car was fixed. You have to know how to solder in order to do this. Thanks for your video, it got me started
Mike Logan where is your video
@@WestcoastBattleRap Go to Mike's video list and you will see it.
I found a much easier way. Wire in a separate fuel pump relay and bypass the onboard relay. ua-cam.com/video/YNvWK4pV9E0/v-deo.html
@@dudethman1000 I think that is a better solution. Wiring the relay does 2 things. 1. lets you replace it if it burns out again 2. The external relay has a higher current capacity.
I took mine apart and there was no indication of burnt relay or any hot spots around that relay at all , but shuts off while driving . I changed the fuel pump and fuel filter and still nothing
Thank you for this heads up, my 2003 F-250 had the same symptoms, 5.4L gas engine!!! 3 fuel pump replacements and finally no start at all. Service Manager from Ford dealer said there was nothing wrong with the fuse box. Ordered a replacement on ebay for $100 plugged everything in and the truck runs like a champ again. Only about an hour job, thank you again!!! You were right on!!!!
did U go back to dealer and get your MONEY back damn crooks
OMG! Thank you soooo much!!! I have been dealing with this issue for over a year now where my truck would just shut off for no reason. Sometimes it would start right back up , sometimes not. It would go a few months or more without a problem then one morning, nothing. Was told by a good friend, mechanic for 25 years, that it was probably the fuel pump, which I had already thought . Came across this video while trying to locate R303 location as a last resort and bam, here we go. Just pulled fuse box out and there you have it, middle relay burned in the same location, plus white smoke dust. Once I had the board in my hands, you could really small the burnt electrical. About to order new one now. Thanks!!!!!!!!!
Did it fix the problem?
You are a life saver. I just had this happen to my 2003 Ford Expedition and I changed the fuel filter then the pump thinking I solved the issue. I was driving down the highway and again car just shuts off and would not restart until the next morning. I saw your video and went to the junkyard and got a fuse junction box and installed it, and sure enough my previous fuse was burned on the corner just like yours. Thanks so much for this video!!!
Thanks for posting this video. I have a 2004 Expedition 5.4L that was experiencing random stalling with no codes. When I removed the fuse box, I found that the relay that controls the fuel pump was slightly burned just as described. Replaced the fuse box and the problem was corrected.
Eagle VA013 change the box.
where did you get it from if you don't mind me asking?
Charles Thompson does it matter if it's a 4.6 or 5.4 or is it the same relay junction box? Thanks
You can change the relay for ~$15 if you have any soldering skills. If not, remove the board and find someone who does. Just need an iron and a solder sucker device. Thanks for all of the other pertinent and helpful information. It helped me complete this in the dark at my work parking lot. Also, caution about those tabs. they need to be orientated the correct way else the plug in relays won't fit properly. Just be sure to do a quick plug in test for alignment prior reassemble.
Thats exactly what i did to mines no need for anew one just replace the relay and its good its been over 5 years and still kicking! Just replace the relay they are easy to find.
@@joseone69 when you say relay you mean the actual fuse or you mean the green chip inside the box I’m having the same issue
@@spiritualak5147 it is a relay inside the fuse box you can not see if if you don’t open the fuse box it will have a row of relays but one is for the fuel pump, i dont know why ford would design it like that i think this just stupid and for the have consumer waste $500.00 on anew fuse box when it can be fix simply.
@@spiritualak5147 i found the relay on ebay just get the part number of the it and order, i know i have a working spare fuse box , im looking for it as i write.
@@spiritualak5147 ok i found it and there is a row of small relays but they are under the surface and is the middle square relay original part number is F8VF-BA and you can replace it with F4FL-AA relay they do same function and is omron brand too. Remember is the very middle one that is fuel pump relay hope this help , like i said i have spare one let me know if anything
Great tutorial, I am having the same problem with my 03 Expedition and at first we thought it was the fuel pump. After a week of driving with the new fuel pump, the problem came back. I will definitely be doing this to fix this issue once and for all.
!!!!!!!!!!!!!!!!!!!!!!!!! I hope this got someone's attention if you're getting ready to do this job. IF THE GROUND WIRE CONNECTED TO THE FUSE BOX IS STILL GOOD (WHICH IT PROBABLY WILL BE), YOU DO NOT HAVE TO RUN THE NEW CABLE THROUGH THE FIREWALL. YOU CAN JUST USE THE OLD ONE. There's a cover over the ground wire on the fuse box. Remove the cover and a bolt will be exposed (10mm bolt i believe). Unscrew that and the fuse box will be free from the ground wire. This will save you SO much time and headache. The cover is a little annoying to get off, but I just used a small flat head screw driver and lifted it up on each side. This is an easy fix. You may have to use a very little bit of muscle when removing the panel that's stuck underneath the door guard rubber. Very easy fix though. Great vid by the way
I have an 2003 Expedition and was told today, this is my problem. Thank you so much for the presentation. Aloha
Hello Alex! thanks for this helpful video. I've had my fuel pump and relay replaced along with many other things. Now the mechanic is saying it's the fuse box. My '03 expedition keeps cutting off. Sometimes it will start right back up, and other times as you said it can take up to an hour. I was getting so frustrated to the point of selling it, but I feel this could be the underlying issue. My husband and I will try this, but this will be the last ford I purchase. Too many problems that don't show up until you have spent hundreds of dollars on things that probably weren't even an issue.
Alex, Thanks for video on replacing the 2003 Ford Expedition Fuse Box assembly. I had exactly this problem with the fuel pump relay. It overheated and melted the solder joint on one of the circuit board pins so that it would randomly stop powering the fuel pump. I took it a step further and replaced the relay on the circuit board. Put it all back together and all seems fine. The replacement relay is available from Digi-Key (800 344-4539) for around $4.25. Part Number Z2696-ND (mfg p/n G8Qn-1C4 DC12 Omron Electronics). Thanks again. You saved me about $350 dollars for a new fuse box.
I'm glad it worked out for you. I wish I would have tried to replace just the relay. It is difficult to replace and solder back in place?
Alex S Good video, thanks for sharing. This water leak and fuse box damage seems to be an issue with the Expeditions over several years! As far as repairing the fuse box, it's not something the average person can or should do as you could do more damage to the circuit board, but you could always order the new relay and take the parts to a local electronics repair shop and have them do it for you. They shouldn't charge you more than $20 to fix it.
How did you determine that the Z2696-ND was the correct replacement?
Google usually works for me and also the Ford dealer parts dept will give you the part numbers if you ask for them.
Is this relay interchangeable? I had a PCM Relay go out in my 2003 Navigator and wondering if this same fix would be possible? I'd love to not have to spend $350 on a new fuse box.
Thanks for taking the time to make this video. I went right to the problem and fixed it.
Exactly as described.
I have solved this same problem by simply unsoldering and replacing the fuel pump relay on the PCB. This avoids the replacement expense of the whole PCB assembly. Such relays are found online at very low cost.
My .02, it is the fuse box. there is a manufacturer defect in the vehicle itself with water/moisture intrusion.
The moisture gets on the card/box and wreaks havoc on the electrical components. It's a subtle process, but when it hits it will leave you stranded like a big dog.
I also asked for a dealer quote and got a price of $800 to remove and replace. The brand new part at the dealer is between $450 - $600. Used are $150. The used are like trying to find a decent politician, nearly impossible. The used do exist, but you will be on the hunt on your phone for a minute.
I LOVE my truck, but this is the only issue I have ever had with it. Too bad it is a huge problem when it hits.
Best of luck to all my fellow Triton Expedition owners.
Hi Alex, in the behalf of my family I would like to thank you for the video you post on youtube.
that solve my problem in the first try, that was awesome Alex thank you and GOD bless you. :-)
I have a similar problem with mine but with battery saver relay (304). Thank you for this video, I didn't want to break anything so this helped me take mine off flawless.
Was it running straight off the battery and not the alternator
Wasn't running straight off the battery and not the alternator
Alex great video and explanation my 2004 Ford Expedition truck is doing that right now !
Bought a used fuse box and did the swap...Thanks for the video.
Thanks Alex S and Mike Logan. A very big help
03 expedition had the same stalling issue, no crank, no power to starter, half the electrical worked. Bought a replacement relay and desolder the burnt one and solder the new one (done by a specialist ) and that did not fix the problem. Bought a used fuse box $65 ebay of a 04 navigator wrecked covered in snow the seller assured me it was interchangeable with expy and in working condition. Installed it my self 15-20 min and started right up haven't had one stalling issue since and all electrical is working 100%. Do it yourself really easy. Dealer $350 for fuse box and $500 for 20 min labor job wonder what they do the other 4 hours?
tip for any one facing this problem, lookup "Omron Relay p/n F8VF-BA" cost $12 plus a couple bucks solder job will get you back on the road
Good job on the video brother, was just what i was lookung for. Thank you!
Nice video and write-up. Thanks for posting!
Same problem with my 03 navigator , relay kept burning out found a used fuse box on eBay for 60$ it's been 1 year now and no more burnt relays.
Does installing a new box require the keys to be reprogrammed. Or is the box ready to use no programming necessary ?
@Alex S, thank you so much for posting and sharing this information. @Rich V, thank you for sharing the replacement Relay supplier’s name, phone number, and price. I called Digi-Key Electronics (800-344-4539) and ordered the relay. Now, the particular part # you ordered is out-of-stock so I ordered the cross reference, Panasonic P/N JJM1-12V (Digi-Key P/N 255-2220-ND) at $3.55 + shipping.
I actually already bought and had my mechanic install yesterday a brand new Fuse Box Assembly on my 2004 Ford Expedition E.B. with 245K miles, but I’m still replacing the burnt Fuel Pump Relay on old Fuse Box Assembly as a back-up or if anyone is interested to buy the reconditioned Fuse Box Assembly. @Alex S is 100% correct because the damaged relay is exactly where he said it is!👍🏻 My Expedition was experiencing the same exact symptom: sudden engine shut off while operating the vehicle; no engine light nor codes whatsoever. It first happened some 18 months ago, and it happened like 3 times (the last time was only this June 14, 2020). And, just like many, I brought it to the dealer and they can’t find anything, not even a clue! After reading this post by @Alex S and before I had the new Fuse Box Assembly installed, I called and was told by the dealer it would cost $891++ to replace the Fuse Box. Good luck people!
Thanks Alex! That is the problem that I am having now.
great job. very useful for modern ford power boxes
One can buy the non-serviceable fuses (OMRON F8VF-BA 12VDC or G8QN 12VDC). They range from 3 to 15 dollars each.
You can buy relay's on the parts stores 2 for $12.oo and un soder the old one and replace the relay with a new one put it back together and put it back in the truck it will run like a new truck . Take the hot post of the battery before you start the take a jumper cable on the disconnect hot cable and put the other end one the still connected ground cable do not let the hot cable touch the hot post on the battery wrap it with a rag and keep it away from the hot post so it doesn't ark on the post .when you do that for about 30 minutes it will clear all the bad codes and when you put the fuse box back in re connected the hot cable back on the battery and then restart the truck and go through the restart drive very slow and not fast it will reprogram your truck and it will drive like it new .you will save hundreds of dollars. Look on Amazon for your new relays thank you for your video
Great vid, What's the exact vehicle for this video your doing . I have a 2003 Ford expedition Eddie Bauer 5.4L 4WD. If you don't mind me asking ,What's your vehicle that this fuse box came from . Thanks
I resoldered the connection and haven't had a problem in two months. What happens is the relay get to hot from possibly a bad fuel pump causing to much resistance and overheats the connection and de solders it. Re solder it and clean the relay! You do have to remove the relay cover.
Having the same issue but I don’t get an OBD2 code. Did you have the same problem?
I went through the same exact problem, but i was able to find one at a truck salvage yard. Great Video BTW. My question is. I have my old one now & if this problem happens again in the future is there a way a could solder one of the other 5 relays to replace the burned out one? Is all the other relays the same? I was hoping that i could solder 1 of the other relays from my old fuse box into my other one if it is posible? Any help on that would be Greatly appreciated. I own it & woud love to keep it, so in the future maybe this could be possible? Thanks for any help. Again Great Video!
Same problem 04 EB 5.4L expedition-- Ford quoted $1600 to replace pump and fuse box.. I intend to replace the box, but should I replace pump too? They said both were bad...
Thanks, brother for the vid, was very helpful and well explained
i need help i have a 97 expedition and its cranks but wont start i live in san diego. i have had the shift interlock selenoid replaced because it wouldnt go into gear and the and the some other things its now the original key to the car but i never had a problem with it though and the theft light is blinking
Actually this is a standard size pcb relay SRD-12vdc you can get like 10 for $8 in ebay
Alex, nice job.. I have a question... If the fuse box is completely unplugged as if just changed, do i need to have the PCM reset/flashed or whatever they say they need to do at the dealership? Or can i just plug and play? I thought I would at least disconnect battery and cross + and - for 10 min to completely drain memory and hopefully reset and get rid of my problem.
My problem is that i had a drain on battery (9.49) on volt mter... I only disconnected fuse box to eliminate all circuits. It did not and now dash says all doors are ajar and can't get it out of park. all i did was to unplug fuse box. Any suggestions?
Thanks,
Frustrated with Ford
I think I may be headed toward this failure in my 2003. The engine will stumble or stall out completely at highway speeds. I coast on to the shoulder and it cranks right back up. It used to happen once or twice a month but last week it happened 3 times in one day. No rhyme or reason, No engine light or other electrical issues. I heard something about the alternator wire chaffing and shorting out on the AC piping on some Expeditions but im not sure if that's what I'm dealing with
Do it have to be programmed to vehicle your replacement?
thank u i thought mines was the fuel pump. Same issue as yours. Now my truck won't start and saying low oil pressure. I did this step and mines burnt. Ordered the part and hopefully this will fix the problem.
Update?? Please!!
Thanks for this video! Showed me exactly what to do!
Hi I have a question I hope somebody can answer. I have the same problem but with a 2004 expedition. I was told to replace the fuse box. But would it make sense to buy a fuse box from a year not affected by this problem or should a buy a fuse box from the same year?
The relay that is replaceable on these are some times loose and it will make the vehicle die replace the relay and good for a while so took out fuse box soldered the back side on the plate where the relay goes and thank full to GOD it has been good for over 2 yrs!
What website did u buy the replacement from? Thanks
I have the same problem with my 04 Lincoln navigation change fuelpump still happens changed a fuse it was fine for a wale did again so kinda thnking of do what u did maybe jest to check if the board is damaged sinces it out y not replace well the point is do thnk could have the same problem would like feed back thnk u.
My check engine light has also come back on. I understand now why fords are ( found on the road dead). The ford dealership couldn't even diagnose it as the fuse box until I had my breakbooster, fuel pump, fuel relay, a tune-up and a host of other things.It was the last code to show up. Maybe I needed some of those things anyway, but I'm almost certain that this is my main issue of stalling out.
Pcm relay@kevin warren. I have an 03 expedition manufactured in jan 03. Early model year expedition/navigators have a different relay/module control units vs units manufactured later in the year. It is a very common problem with early 2003 expedition. Every few months I would insert the key and would be greeted by a loud buzzing noise coming from the relay box by the passenger kick panel. I purchased several little relays and kept them in the glove box. Eventually the box started to burn and the replacing the modules no longer worked. The box is relatively easy to replace if you mechanically comfortable but a novice can do it as well. The biggest challenge is running the plug thru the firewall to the computer. THE FUSE BOX ISSUE IS DIFFERENT FROM THE RELAY /MODULE CONTROL BOX ISSUE
Mine is buzzing and also having to change out relays. What exactly did you replace?
The box that the relays plug into. Passenger side kick panel
You may be able to get away with swapping or replacing the relay that is buzzing but it will eventually give out completely.
Ok thanks! This issue started over 4 years ago and changed 3 relays in those 4 years. In the past 6 months I've changed 3 counting today so it sounds like it's on its way to completely going out.
I played the game for 4 yrs myself it sounds like your close to complete failure
Can you post a demonstration video on exactly how to remove the fuse box
Are the fuse box for a 04 Expedition and a 03 Expedition compatible
Thank you very much for making this video
Hi Alex,Where did you purchase the fuse box?
I have the same problem where you find the fuse box thank you for your help we should help I heard from you
Update: So my husband and I went to a local pull-apart which has junked cars. They had one '03 which thankfully still had the fusebox. We removed it, and just put it on without changing any of the fuses. My truck fired right up!! hasn't cut off since. I'm praying that it doesn't. The mechanic told us that we would have to buy a new one from ford which would cost us around $700. We paid $30
+Aaron Wilson When we got the used one I told my husband to put it on as is. We didn't remove those fuses or anything. We just connected it back to the ground wire, and screwed it back against the panel. It works just fine, but of course I kept my old box with fuses. I really hope you get your truck fixed. This video was a lifesaver, because I didn't really know what was causing the truck to cut off. If you can find another fuse box cheap I would advise putting the used one on first. It only takes about 15 minutes before you go through changing all those fuses.
Did the new fuse box fix your problem?
hey alex did the truck ever skip as it was going down the road?
+William Leggett William my 2204 Expedition does that , I found the problem was the Combined coil and spark plug assembly. Just do a diagnostics to find out which one of the 8 cylinders is doing it and replace it , its easy to do , cost was about 40 bucks.
No. It would just die. Initially I could place it in park while rolling, crank the key and start it back up.
Townman1, these are two seperate problems. Coil over plugs do not cause the engine to randomly and entirely shut down. When the coils fail, engine still runs, unless all coils fail at the same time - highly unlikely.
Where did you buy the fuse box online?
Great job Alex!! Thank You.!
He'll I have a expedition 2003 I recently replace the battery and the alternator but after running it half an hour to an hour it just dies completely and drain the battery out can this be fuse box problem??? pls help
My expedition is a 2004 and I am having a problem where i have no power to the dash or interior Accessories. I installed led brake lights and i went to turn the ignition on and i heard a pop and saw smoke. Now after replacing the starting it starts up but it still doesnt have power to the inside. Is this a sign to a blown fuse box
YES
como puedo quitar caja de fucibles de expedition 2003
How long would a new fuse box would last if you replace the whole unit
My 03 expedition has a fluid leak somewhere that shorted out my fuse panel. Find the issue that caused the panel to go out I'm guessing
Thanks that's just what I needed..
I would have unsoldered the burnt relay and switched it with another relay that is less important if it failed then try and find a substitute relay. Auto makers build planned obsolescence into their products to make a good profit on the upkeep of their products.
Another cheaper fix than putting the OEM fuse box back in, is to cut the wires leading to the fusebox and then buy a $5 relay and solder those same wires back onto that relay. Works perfectly...Also caution on buying "used" fuse boxes on the internet - you have no idea how many miles (running hours) are on the used box, so you could set yourself up for failure again if you get an old one.
You don't need to unsolder the old burnt relay, because you are taking it out of the program buy cutting the jumpers that are going to the relay in the first place.
Most folks are not technical enough to unsolder parts off of a circuit board, and you may damage the board by attempting the suggestion above.
Better to cut the wires, and re-attach to new $5 buck relay.
Instructions for such are on the web.
Additional information from further up above remarks, this particular problem is annunciated, so there are no codes. Other problems such as COP, or spark plug issues are annunciated on the code computer.
Also where do I but it from
Hello, Question: Is the fuse box of an 05 same as the 03 for a Ford expedition 4x4 5.4 triton????help please??
Siquen Chavez It should be the same
Thanks Alex S
so basically it will happen again?
Great video. Thanks.
from:
www.ford-trucks.com/forums/1183363-5-4l-super-duty-stalls-randomly.html
wire diagram is found on the above page too.
I have dealt with this for a couple of years now. I changed multiple components including fuel pump to avoid purchasing the $600.00 fuse block that has the fuel pump relay built into it. I screwed around with this for too long not to share this helpful hint
First
Let me help you determine if your problem is the relay. remove the passengers side kick panel. behind it you will see the inertia fuel shutoff switch. It has a reset button on top of it and has a plug on the bottom of it with a green and yellow wire on one side and a purple or pink and black on the other.
hook a test light onto the green and yellow wire. start the truck. Drive or what ever. you need to watch the light to see if it goes out just before the truck dies.
* If the light goes out just before it dies it is your fuel pump relay.
* If the truck dies and then the light goes out after it dies then most likely computer (PCM)
* If the truck dies and you have ---------- where the odometer mileage reading is likely computer (PCM)
Second
Cheep Fix to fix fuel pump relay. Simply cut the green and yellow wire. (RED MARK ON ATTACHMENT) Then on the inertia fuel shutoff switch side of the wire hook up a new $5.00 relay. Be sure the relay powers up when your key is in the start and run position.
************************
So I want to wire the relay up I'm just not quite sure how... What side of relay do I put the green and yellow to ?
And then just cap the other side of the green and yellow off? Also can I pull power to the relay from the orange and black wire from the inertia switch as well?
*************************
Looking at the bottom of a relay you will see numbers for each terminal.
#30 will go to your battery with a fuse in line. (Constant power)
#87 will go to the inertia fuel shutoff switch the DG/YE wire
#85 will go to ground
#86 will go to the fuse block or any power wire that when your key is in the start and/or run position it has power. This is important. If you hook it to a constant 12 volts your fuel pump will run constantly.
Yes the other wire gets caped off
I hope this thread has been helping people
******************************************
Thanks, that was really helpful
what is that part number i can not see it
Can anyone Answer If they bought the new fuse Box and Installed it if The car ever stalled again?
WHAT? got your attention. I bought a used box with fuses from a guy, i took the old one out and PUT THE NEW ONE IN. NOW THE DASH SAY "CHECK CHARGING SYSTEM" Next thing i know my alternator dies 6 days later. Suggestions??
what are the odds of this happening again? I have a grandbaby on the way in August and don't wanna have my expedition down and not be able to get to the hospital. I have also heard horror stories of someone changing theirs out and their truck burnt to the ground that night while they were sleeping!
Also, let me add Thak you Alex S, your video is much appreciated by us all, whether we needed to know what was wrong, or needed somewhere to get started. You helped accomplish that!
There are people who repair the fuel pump relays with life time warranties. Had mine repaired for $56,
What a GREAT video. I was able to fix mine, wiring in a separate relay. www.pirate4x4.com/forum/ford/1696970-need-help-mcgyvering-ford-fuel-pump-relay-04-expedition.html
Mine was kinda easy to figure out, when I got to the fuse block assembly, I could smell burnt electrical. Because of your awesome video I still went ahead and took it apart with confidence. Found exactly what you found. Yeah I could have replaced the fuse block, or replaced the relay, but 7pm on a sunday night, I justed wired a new one in. Thanks again for a great video.
Bradley
Thank You
Great video
ive blown 50 stsrter relay fuses in 3 months freak. 700 dollars in relay fuses. some1 plz help. i cant figure out why randomly popping relays. and we need our vehicle working . down to bout 5 fuses left then broke. i have no idea what could be causing this shit. it randomly pops the fuse while driving. now its loose where they go in from changing it so many times sometimes i have to wiggle it
If your power supply cable is good, no need to replace. Save yourself some time
so far I have replaced the fuel pump and the positive battery cable and it still died out whenever... lately is died and would not start at all had it towed to fritz ford riverside where all the other work was done and they came to the conclusion it was the fuel relay in the fuse box wanted over 800 bucks I said hell no due to the fact I already paid out that much in other repairs they said would fix it and did not.. I will pick it up to tomorrow paying for all the part 400 + and see what happens .. better be fixed or else the Ford Corp is going to have a crazy woman on their hands as well as the dealership and I will blow their shop up on yelp and any other social media I can... peace out wish me luck
Cool. Did it work for you after replacing it? Hope it did.
Sooo helpful
how do it cost man wtf i need to no wat it cost to change hold fuse boxs dammm:*(?????
Just curious...but...why didn't you just solder on a new Relay...would've cost like $10.00...besides going to a junkyard and getting a used one for cheap?
Use 250$$$
Or you can buy a $20 relay instead of the $300 fuse box, desolder the burned one and solder in the new one. It's not too hard to do if you know your way around a soldering iron. :)
why not just solder a bypass wire on the rely terminals and save ?
+JIM Koritzer one questen please have you any idea how i can fix my ford mondeo mk3 2002yr 20 tdci i have fault code 1631 somthing with bad relay of CMU but that hapend after bad glow plugs, my fuse of glowplug is out and car stop working ,i have change new glowplugs and new fuse now is ok but i cant start my car anymore becouse of that fault code 1631 and cant delete MY QUESTEN IS HOW I CAN BRING PLUS AND MINUS DIREKT ON RELAY TO TRY DELETE THAT ISSUE BECOUSE SOME ELEKTRIKER SAYS TRY TO BRING PLUS AND MINUS DIREKTLY ,BUT HOW?? THANK YOU M8
ua-cam.com/video/U6Nd65lAZU8/v-deo.html
Check components and maybe your pump is the issue. The fuel driver control module could be an issue that burns the soldering in the fuse box/junction box.
i went to get one at pick and pull for 35.00
All you had to do was order a new relay and unsolder the old one and solder in the new one and spent $9 dollars for the relay
i have a different problem, but i think you might be the person to help me...long story short - electrical gremlins so i want to take the fusebox out and check it... i TRIED taking out the fusebox - there is one screw on the door side, but i can't see what the heck is holding it in place on the inside closest to the motor. there is the black cable coming through the firewall, (would be great to get a close up of that - if your eyes can see if, your hands can 'feel' it), is there anything ELSE holding it in?another screw at the back or something? thanks
+one less rat the black cable has has a cover and under that cover is where the box is bolted down
lcheffin same as mine... i don't know how these big burly guys manage this stuff - i'm a small woman and i practically had to grease myself like a long distance swimmer to get under there!! but the cover comes off - it's just weird when you have to let your fingers FEEL that it looks like... but look at the fuse box on other vids out of the car and you can sort of see what it should look like
Omg Im so lucky i jus paid 50 dollars for mine cause I know somebody that knows somebody lol
Why didn't you show removal??? Thumbs down for incompleteness because you can't replace until you take out!!!
I just took apart a clients 03 exped fuse box and all I have to say is FORD is full of ****!!!!!
The lie is that if one of the five relays go bad that it can't be repaired and that the part can't be purchased! That's a flat out lie, These relays are available and the circuit board can be repaired by a dummy much lest a human! if you don't know what you are talking about, just keep your mouth closed and stop forcing people to spend money on a new circuit board or get rid of their vehicle. Do your research first!
OK video, BUT....why in a world, you did not replace that one relay, in a middle for fuel pump??? After all this work, piece of cake, new relay in ebay, cost $8-12 only, and just unsolder old one, which in made in China??/, Ford uses cheap, underrated relays, new ones are better, made in Korea!!! Nothing else is wrong with this fuse box!!! And , no, you don't have to replace, or take out cable going to battery, just open the nut in fusebox, leave the cable there, nothing wrong with cable, clean connections sure!!! So there,...you save $400....;o)