Good afternoon all. This past week my 2004 FX4 just died while driving along. No sputter or anything. Just shut off. Tried starting but it would just turn over continuously as if getting little to no gas. As a matter of fact, it was the same symptom I got last year which turned out to be the crank position sensor. See this post for history (https://www.f150forum.com/f4/engine-...n-dies-511414/). Got a tow and when I got back, I pulled the connector to the Fuel Pump Driver Module and installed two 15A fuses to turn the fuel pump on continuously. This was successful. I plugged the connector back in and it started but was hesitant to do so. I had just replaced the FPDM with a Dorman back in Oct/November of last year. I proceeded to order a Motorcraft and installed it yesterday. Still, every now and then, it will still turnover a good 4-5 seconds before starting and other times it fires right up. I also replaced the fuel pump and filter earlier this year with a Bosch since the lead time for the Motorcraft was so long. Any thoughts?

And it's happens randomly, not just on cold start or something like that. No codes either.

 

I'm having the same problem I think so curious what it turns out to be before I waste time and money. My truck just almost left me stranded today in a parking lot, but after trying to start it many times and calling a tow truck, about 30 min later I tried again and it fired right up, so didn't need the tow. I had a long crank happen only one or two other times but never just totally stopped like it did today. Now I'm scared to drive it because don't want to be stranded.

Mine is a 2013 5.0, but sounds like the same issue.

 

Take a look at this video and test your canister purge valve. Takes five minutes.

 

I don't believe this video is applicable to the 2004 model like mine.

 

I checked fuel pressure prior to and during startup and it is good (+40 psi). I have noticed that when it struggles to start, it runs roughly the first 15-30 seconds after starting. My Torque pro app tells me that it is cylinder 5 misfiring when this happens. Could a leaky or bad fuel injector at cylinder 5 be causing the occasional startup issues?

 

I see you have a reman with 24k miles . You moved fuel injectors over when you did swap ? I believe in changing same after 100k mi with new not reman as they have a high duty cycle. Or at least build a small test station and clean them and observe spray pattern . A leaky one can hydro the engine and ruin it .
But besides that ,long ago I changed fpdm which caused it to intermittently shut down in days or weeks ,after stranding me in the heat beside the road going back and forth between the old fpdm and new . I fought it until I noticed a rolled gasket in connector , pulled it out and it has been good for many years. I believe it was pushing connector apart at times .

 

Yes. All fuel injectors were swapped over with the replacement engine.