Hey everybody, I have been searching the forum for a couple of days now to see if anyone is having the same problem that I am, but I have had no such luck.
I have a 2006 F150 XLT 5.4L V8 with 153000miles on her. I love my truck to death except for the past week. I bought her in Feb 2012 and this is the first major problem I have had with her.

On Sunday I was on my way out to work when I decided to stop for breakfast. I took a Left into the lot and my truck just died with no warning. When she dies the battery light and the wrench (service) light come on and the small LED screen says Check Gauges. I tried and tried to get her to restart with no luck, she'll turn over all day, but she just won't start. I had to call my dad to come tow me to my house. I got her to start on starter fluid for about 1min and then she would shut off again so I know I am getting spark. About 3 hours after we got her home I went out to take a look and just before I did I thought I would give it one more try and she started right up with no problem.

On Tuesday I was on my way to the auto store to get some things and as I made the Left turn at the light she died with no warning, but with all the lights and the Check Gauges just like the last time, and I had to coast her into the parking lot. Once again I tried to start her up with no luck, she'll turn over but she won't start. I checked all the fuses that have to do with the fuel system and all of them were good, and the inertia switch was not tripped. I unplugged the fuel pump driver module and plugged it back in, nothing. I cleaned the minimal corrosion on the battery, no change. I unplugged all three of the plugs into the computer underneath the hood and put dielectric grease on them and plugged them back in, still no change. I took the fuel line off the bottom of the fuel filter and turned the key, the fuel pump primes and has pressure. I took the fuel line off the front of the fuel filter and fuel comes through just fine. I took the fuel pressure sensor off the rail and it shot a bolt across the parking lot from all the pressure behind it, put it back on and plugged it in. I replaced the two cam position sensors and that did not help at all either. Unplugged the MAF, still wouldn't start, plugged it back in. Towed the truck home again.

On Thursday, I saw on a thread that someone had a similar situation and it was their key that was causing all the probelms. I went out and started her up and let her run parked in the drive way, she'll start up with either key. She got up to operating temperature and then died 5min later. No start with either key. I checked all of the plugs to the fuel injectors and the coils, all were connected.

When she runs, she runs just fine, no sputtering/bucking/rpm jumps...nothing. All of her gauges read normal: temperature, battery, oil pressure

So far we have ruled out:
1. both keys
2. MAF
3. Cam position sensors
4. fuel filter
5. fuel pump (unless it could be weak and causing the problems)
6. plugs/spark

She has, under the hood,:
1. 8 new spark plugs
2. 8 new coils
3. 2 new cam position sensors
4. new oil change, with about 1,000mi on the oil
5. new transmission coolant line (other was leaking at the radiator)
6. flushed and refilled the coolant system with fresh fluids
7. new air filter
8. new serpentine belt
9. new fuel filter


Does anybody know what it could be? Why it will start and run, die, and then not start again for at least 3-4 hours? I am worried that it is the computer itself under the hood. Any insight? I'm STUMPED!

 

1) drop spare tire.

2) look above spare tire on frame rail.

3) remove corroded out Fuel Pump Driver Module

4) install new FPDM.

Drive happily until the replacement FPDM rots out.

 

agreed!

 

it didn't look corroded when I looked up under there..could it be corroded and not look like it is?

 

sounds like a fuel pump issue so yea id look at the fpdm i would just take it out and look at it it corrodes on the back.

 

They corrode on the backside due to dissimilar metal (aluminum against steel). You won't necessarily see the corrosion until you pull it off.

 

I have one thing to say... DONT TURN LEFT sorry i had a truck dying problem but its not the same as yours

 

Okay, thanks y'all..I will make sure to pull it off tomorrow to see what the verdict is, I already have the spare dropped so I can get to it. I'm praying that this is the solution!! I miss driving my truck.

Lol Red1999XLT, I'll make sure to take the long way around to avoid taking a left..

My dad and I have a plan that might keep it from corroding for as long as I will have the truck, if it infact is the one causing me all the grief. We plan to dip it in epoxy, not the whole thing just the bottom half, and then put rubber bushings on it to keep it off the frame, just a little bit of clearance to prolong the life of the FPDM as much as possible. What do y'all think?

 

THe new FPDMs should have that problem taken care of, however, it it's bare aluminum, at a minimum I'd coat it where it attaches to the frame. Being that you're in Tx, I'd just use the bushings, dipping it might have a negative effect on the electronics, they use aluminum for the housings in many cases as a heat radiator.

 

Mine was doing the same thing on occasion as well.. Only once truck was well warmed up and usually when putting it into reverse.

Yesterday I changed the FPDM. So far so good. Will report back with progress.