I have a 2005 4.6 4x4 with 180xxx miles. It will randomly stall and die. When it dies, I put it in park, turn it off and back on, and it runs rough for about 5 feet and dies again. To me it feels like it is starving for fuel. Then for seemingly no reason, it will start running again. One time when it happened I got a check engine light and a fuel rail pressure code. I believe I have replaced the whole fuel system at this point but I have to be missing something. The first think I replaced was the FPDM. I was unsure of the age and know they are known to be problematic. I got a new Dorman unit with the rubber standoffs. I also replaced the FPDM connector as the other one had a broken clip and needed to be held on with a zip tie. I also removed the ground wire and cleaned up the connection very well. I also cleaned up the ground in the passenger footwell and a couple under the hood on the firewall. Next as a maintenance item I replaced the fuel filter. I dropped the tank and replaced the fuel pump with a new Bosch pump and the fuel rail pressure sensor. I was battling another issue and removed all of the fuel injectors and had them tested and cleaned. Two were faulty and I replaced them with new Motorcraft injectors. Today my son and I took it for a test drive and made it about half a mile before it started acting up. We were driving at about 10MPH and it did a little surge and died. We were able to turn it off and back on, move 5 feet at a time, and get home using gravity and some well placed hills. Once we got home I grabbed my laptop and OBD scanner to hook it up and pull some data. Welp, guess what? It won't do it when I have my scanner plugged in. We drove around for probably 5 miles and not a single surge. I had to call it quits for a couple reasons, I can't take this thing out on a busy road because I don't want to get stuck in heavy traffic and after 50 laps around the block I think the neighbors were starting to worry, and my frustration was growing to an unhealthy point.

What am I missing or what else could cause this behavior? Intermittent stalling (feels like loss of fuel pressure) but starts back up to only move a few feet before stalling again. Then runs fine when I am monitoring fuel pressure. It currently doesn't have a CEL or any stored codes.

 

duplicate post

 

i skimmed this post; didn’t see any actual fuel psi data. try to get access to a device that can monitor fuel psi, report back with what it is at key on prior to start, what it is while running, and what it is during failure.

if you can’t get that device; have some starting fluid ready (and ability to quickly remove intake tubing). when in no start condition, spray fluid directly into the TB. then try to start. does it pop/fire up briefly?

repirt back with details/findings

 

fuel PSI is 40 at key on then 32-38 when running correctly. I swear the truck knows when I am watching and it will not act up when I am logging fuel data.

 

those are a little low, but will run. you really need to monitor (and report back) what psi does when it fails (to determine if in fact thi usa fuel problem).

 

if you really think that is true, then unplug it, get it to failure state, and be ready to try the starting fluid spray test.

another thing that may be worth checking, find the black plastic box/cover along frame under drivers seat area. remove cover and see if connectors are packed full of mud/wetness and/or that connector is still fully clicked tight /connected. . not saying i think that’s the case, but easy to check and rule out.

 

If you have a Dorman driver module, that might be no good
Some only last a week or a day
Yours should be above the spare tire, right?
Your 05 also could have a fuel pump relay in the PDC (underhood fuse box)
I'd have a 2005 truck EVTM out for the vehicle, looking at the fuel pump circuit, there are liable to be a few variants