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Ford TaurusAlong the way, Ford has made some 500 changes to the Taurus, changes that were already scheduled for the mid-cycle freshening of the Five Hundred. The general body shape of the new Taurus is the same as that of the previous Five Hundred, a large, front-wheel-drive family sedan, but almost everything else has changed for the better.
How low do you allow your fuel tank to get before you stop for more gas? I'v been told you should not let your tank get below a 1/2 tank to keep your fuel pump motor cool and comfortable. No less than a 1/4 tank or your are asking for trouble. Someone mentioned in a previous post that non-Ford aftermarket motors are not very reliable as the Ford ones. I found this out after I had just replaced my fuel pump motor with an aftermarket one, even though it wasn't my problem.
As a second check, how are your ground connections? At battery, engine ground strap/cable, etc.
I have a '92 Taurus GL that was doing the same thing and it IS your fuel level. I never let her get below 1/4 tank anymore and the problem has been eliminated. I put in 3 pumps in 3 years and this last one has been in for almost 5 years now without a problem. 1/4 tank will keep the pump completely submerged and cool. Anything below that and the pump is exposed and it tends to get hot in a hurry.
Fuel level is great advice. Also, make SURE the ground wires are clean. Poor ground draws too much current and overheats the motor windings. That means the body to battery negative ground too.
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I'm a retired ASE Master/L-1 Technician. I still keep current with the latest automotive technology. Visit my blog for cool articles and TSB's: http://free-auto-repair-advice.blogspot.com/
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