Fuel Pump - NOT! I too went through two fuel pumps in two years, as well as a fuel pump relay, which is located in the power distribution box under the hood.
The problem re-occurred a few days after the fuel pump was replaced for the second time - engine cranked OK but no start; and no sound of the fuel pump running when the key is turned to on, (you can hear this if you put your ear to the gas filler tube when you turn the key on).
While inspecting the fuel pump fuse and relays in the power distribution box I thought I head some "electrical type" sounds while I was nudging the box. Sure enough, when I gently shifted the box to the right while someone cranked the engine the fuel pump picked up and the engine started!
It looks like it wasn't the fuel pump or relay at all, but a bad electrical connection in the power distribution box, (this might be the cause of many other electrical problems affecting the Windstar).
I pulled out the relays and sprayed electrical contact cleaner into the sockets. The problem hasn't reappeared in the last 20 - 30 starts, but I hold my breath every time I start it.
I haven't yet checked with a Ford service centre on cost to troubleshoot or replace connectors, or even the entire box. |