JustDarnedFrazzled

Hello all. I'm the very proud owner of a 1995 extended cab 5.0 F150. It's been a great truck and has really been fairly hassle-free since I bought it in '99. It's been so reliable, in fact, that it is my primary vehicle even though it's starting to get long in the tooth, or would that be gear-box?

Several months ago it began the no-start. Engine was turning over, but not seeming to get fuel. I'd come back in a few hours, or a day later, and it would start. I researched this online and that's when my non-mechanical head started imploding.
There could be so many things to check, it was dizzying. The problem began happening more often and of course I could no longer ignore it -- problem was getting it to happen when the mechanics showed up. Finally last week she wouldn't crank and I had Hank the Tank towed to the shop. They kept it three days and wanted to keep it longer to "drive" it but they did change the coil and ignition control module -- I but I needed it for work. I was skeptical, and sure enough, last night Hank had another no-start. Again I poured over the internet and tried a suggested tip -- gently tapping the fuel pump & gas tank with a rubber mallet. Hank fired right up. I am now cautiously waiting for the next no-start to see it this was coincidence or not. I'm quite sure it's the original fuel pump.

For what it's worth, it has two gas tanks and the rear tank stopped working 3 years ago; I never had it repaired because $$ and I only drive it back and forth to work, using my wife's car for other trips.

I simply can't afford to keep towing it to the shop and having parts replaced *****-nilly. I also can't really afford a new vehicle right now. I'm up the creek, up to Hank's axles...

Steve83

Don't let the long list of possible causes overwhelm you - it's an antique vehicle, so there are MANY things that can go wrong. But it's UNlikely for several things to fail simultaneously AND intermittently, so it's probably just one thing that needs repair (NOT necessarily replacement). Pick any ONE potential cause, and diagnose it. If the diagnosis doesn't ID a problem, and you're confident you did it correctly, cross that off the list & pick some other potential cause. Eventually, you'll find something that fails a test, and you'll KNOW it has to be repaired/replaced.

Buy, rent, or borrow a fuel pressure gauge to keep on the truck until the next stall/no-start:


(phone app link)

This diagram distinguished between the "pump" (which is just a motor), the FDM (which contains the pump), and the in-tank unit (which includes the FDM, level sender, & tank plate with tubes):


(phone app link)

The rest of that photo album explains what fails, and how to drop a tank. But the captions of those pics include links that show how to lift the bed (which is probably easier) and how to semi-permanently delete a tank.

Get a Haynes manual to keep in the truck, but READ IT cover-to-cover at least once so you know what's in it:


(phone app link)

The shop shouldn't have blindly replaced the ignition parts - they should have followed the diagnostic procedure in this caption to positively ID the ONE failing component:


(phone app link)

You can keep a copy of that on paper (stuffed into the Haynes, since it doesn't contain that) & the necessary tools in the truck to check it when it acts up. Use this caption to fill in your signature so it's easier for us to help you:


(phone app link)

JustDarnedFrazzled

Wow, that's a very clear outline of how to proceed, Steve. Thank you. Would it be possible to post those links with larger pictures? Those photos/diagrams are tiny and I can't use/see them on my computer (I use a flipphone, so I can't access them via mobile.)

Looks like I am going to have to learn to use a fuel pressure gauge.

I have never had any stalls, just no-starts. Hank runs *great* once he starts, which makes me wonder -- is it possible the fuel pump motor is coming to rest at a worn area which will not allow electrical contact after I shut the truck off?

I don't have a lot of confidence in that this particular shop will be as methodical as you and I know this diagnosis needs to be. I'm considering taking it to someone else and, as you said, have them do things more methodically rather than just switch parts and hope.

Again, I appreciate your help with this pretty maddening problem.

Steve83

Click the thumbnails to enlarge them in a new tab, and read their captions.