Fuel pump issues..the next Ford fiasco?

[da_jokker]

Like the issues with the MIC and Valves, seems like the Fuel pump problems are more than just one here and there. But unlike the other two, I have not seen a thread specificall to discuss this.

Thought maybe I'd start one and see if we can get some attention drawn to this.

For those that don't know because it has been buried inside of other threads, people are being stopped dead in their tracks bevause their fuel pumps just stop. One guy didn't even make it home from the dealer.

What I'm unclear about is if this is limited to the 2.7 or also affects the 2.3? (And if not, what's special or different about the 2.7 fuel pump)? Sound like this is the low pressue pump in the tank (which makes for a very hard trail fix).

Any aftermarket pumps?

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[cowman]

Looks like someone needs to come up with a electric fuel pump kit for these Bronco that will connect to the aux. switches to use when you need too.

 

[Compta38]

I've seen a couple of these fuel pump issues posted here but is it really that widespread or just a couple isolated incedents?

 

[Raptor911]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

 

[Brockdog12]

I went through 6 fuel pumps and 4 EGR valves on my '89 Bronco.

 

[kodiakisland]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

nope

 

[Razorbak86]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

You’re wrong. My tank was 3/4 full and had just been topped off the morning the fuel pump failed on the trail.

My Bronco (2.7L) died today, deep into a remote trail… about 4 miles into a 10-mile-long trail with steep elevation changes, tight turns between narrow groups of trees, and deep mud holes.

That’s it below… hood up, exactly where it died, going down a decline with 21 degree pitch, trailing behind @kodiakisland's Bronco.

For background, @kodiakisland and I were scouting potential trails for the next NWA trail run on June 14th, and @kodiakisland had briefly stopped for a photo, so I pulled up behind him with my foot on the brake. When the engine started to lug, I put the transmission in neutral, engaged the electronic parking brake, and then put the vehicle into park, and it immediately died.

Numerous attempts were made to get it to re-start, but the engine appears to be starved for fuel. The first thing I checked was the fuel pump fuse (Fuse #4, 30A, in the Under Hood Fuse Box), which was fine. The tank was 3/4 full after being topped off this morning with half a tank of regular unleaded before departure. No signs of water in the fuel tank. Popped the cover off the air filter housing and confirmed that the air filter is not clogged or otherwise blocked. The battery is fully charged and alternator is functioning well (i.e., both confirmed by meters on the IP display, 12.4V on battery, 13.3V with alternator charging under load at speed). The starter fires continuously like normal. The crankshaft turns smoothly, and the engine tries to fire, and sometimes does for one stroke, but then dies again. I also disconnected the battery and waited 20 minutes before retrying, but the results were the same.

My instinctive guess is a fuel pump failure (possibly infant mortality; 2,490 miles on the odometer), based on other recent threads posted on the forum, but I haven't had a chance to pull any Diagnostic Trouble Codes (DTCs) or study the Technical Service Manual (TSM) for other possible problems. The vehicle is well beyond cell phone coverage, so it is unlikely that any DTCs would have been uploaded into the Mothership’s tracking system. If it's a fuel pump failure, that is going to present a difficult trail-side fix, because the gas tank will have to be dropped to access the pump.

Unfortunately, it's also going to be difficult to tow out for recovery, because of the aforementioned difficult trail access.

So the bad news is we pulled my Bronco off to the side of the trail and temporarily abandoned it deep in the woods this afternoon, and it is sitting on the trail side all alone in the dark tonight.

The good news is I hitched a ride home with @kodiakisland (Never wheel alone!), got some great photos, and saw three deer today!

 

[JScheier]

I went through 6 fuel pumps and 4 EGR valves on my '89 Bronco.

Number 3 (that I know of) on our 1996. It now has an access hole in the rear floor to make it easier to R&R.

 

[Ksjrb03]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

Wrong. @CUPRA was driving down the freeway when his failed.

 

[MnLakeBum]

At Ford, quality is now Problem 1.

https://www.wsj.com/articles/at-ford-quality-is-now-problem-1-11659758404

 

[JBlanco]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

Correct me if I'm wrong, but do you think this should be the solution to the problem?

 

[Raptor911]

The fuel pump is inside the tank and has to be submerged in the fuel. If you are low on fuel and then hit a steep climb then it could be exposed.

I know there are examples (1) where someone was driving on the road when it failed BUT what was he doing before he was on the road?

If there was an issue with the fuel pump then we would have failure left and right BUT we don't.

Regardless, Bronco6g will call out Ford and there will thousands of post on this

Correct me if I'm wrong, but do you think this should be the solution to the problem?

 

[Dayton1984]

Correct me if I am wrong but From reading all the threads it seems you can avoid this by making sure your tank is FULL when off roading. Once you hit a steep climb with not much fuel, the pump will not be submerge and fail

I’ve read other posts of those with full pumps that failed on and off road so it has to be something else

 

[Raptor911]

maybe there is an issue BUT maybe not. We will never know unless Ford issues a recall

I’ve read other posts of those with full pumps that failed on and off road so it has to be something else

 

[JBlanco]

The fuel pump is inside the tank and has to be submerged in the fuel. If you are low on fuel and then hit a steep climb then it could be exposed.

I know there are examples (1) where someone was driving on the road when it failed BUT what was he doing before he was on the road?

If there was an issue with the fuel pump then we would have failure left and right BUT we don't.

Regardless, Bronco6g will call out Ford and there will thousands of post on this

I understand how a fuel pump works. You mentioned the tank being FULL, and a fuel pump failing on a tank less than FULL in a vehicle designed and promoted as an off-road vehicle due to the fuel level, points to a design failure.
What the owner of the Bronco with the failed pump was doing before it failed is irrelevant if the vehicle was being operated within the capabilities of the design.

If a few fuel pump failures are an isolated occurrence, we can chalk them up to supplier issues. If we start seeing pumps failures at a higher frequency, then it's a quality/design problem.

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