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Old Feb 14, 2024 | 04:27 PM
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From: Orange County, California
Default Fuel Pump Electrical Issues

I want to make sure I add all of the details, so this is going to be a bit long. 1992 F150 302 with 151,000 miles. I am third owner.

Current Issue:
Check engine light comes on intermittently. The trouble seems to stop after a while, but will come back again. When this happens, the following symptoms also appear:
  • I hear crackling through the radio, on one occasion, the radio actually lost power, which came back on in a few seconds.
  • The engine kind of bucks a bit, at one point, while at a complete stop, with my foot on the brake pedal, the truck actually moved forward a few inches.
  • The electrical gauge fluctuates a bit, never out of the normal range but wiggles back and forth.
  • The fuel gauge also fluctuates, going up and down by about a quarter tank.
  • I have an OBD I reader, and I consistently get the following codes from KOEO when I experience these issues: 654 then the separator (10) then 542, 553, 556, 637.
Backstory
I bought it a bit over a year ago, got it cheap and knew it needed a good amount of TLC. Some of the work that follows was done because of issues I knew pre-purchase, some because of problems that popped up as we went along. Here is what has been done:
  • Transmission: Rebuilt the front pump, replaced the pump seal and bushing, and all other seals replaced toque converter. Also added a transmission temp sensor which was cheap and gave me inaccurate temp readings (More on that below). (Did this work myself).
  • Replaced solenoid and solenoid wiring harness. (Did this work myself).
  • Replaced PCM with PCM purchased from Flagship One . (Did this work myself).
  • Replaced spark plugs, wires, distributor and rotor. (Did this work myself).
  • Replaced fuel pressure regulator. (Did this work myself).
  • Replaced electronic ignition module. (Did this work myself).
  • Replaced ignition stator. (Mechanic did this).
  • Replaced starter. (Did this work myself).
  • Replaced ICM, ignition coil, and fuel pump relay. (Did this work myself).
  • Replaced fuel pump and housing. (Mechanic did this).
  • Replaced inertia switch and tightened and cleaned wiring in engine compartment fuse box. (Mechanic did this).
After the initial transmission issues were addressed, I had some trouble with the transmission temp sensor providing high temps. I took it to a reliable transmission shop, and they kept it for two weeks, and said transmission was fine, get rid of the temp gauge and sensor as it is giving me false readings. I have not had transmission issues since the work, and I got rid of the gauge, but I just cut the wire to the sensor and left it in the hole. This might be an issue--see code 654 above.

I have had consistent problems with the truck ceasing to run and then not starting. Hence the ignition, spark and etc...With the replacement of the fuel pump and the PCM, most of these troubles have faded. Also, my mechanic noticed, after fuel pump replace that the wires in the engine compartment fuse box were causing issues, that is why he cleaned and tightened up the wiring.

Now, truck runs fairly consistently (At least it doesn't die on me in middle of road and refuse to start), but I am getting the above described electrical issues pretty much every other day. It will run well, then the engine will start bucking mildly, check engine light, crackly radio and gauge thing, but all will eventually stop only to repeat again in a couple of days.

I am kind of at my with end as to what to look at next. I believe I need to remove that old temp sensor in the transmission, maybe that's why 654, but not sure what to make of 542 553 556 637, all related to fuel pump relay. Any thoughts are appreciated.
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