NHTSA Complaint #11055485 — 2004 FORD EXPEDITION

THE VEHICLE SHUTS OFF WHILE DRIVING (AT ANY SPEED) AND OFTEN WITHOUT WARNING. IN ADDITION, THE VEHICLE MAY ALSO NOT START AT ALL THEN START WITHOUT EXPLANATION. THE MOST COMMON RECOMMENDATION IS TO REPLACE THE FUEL RELAY. TO DO SO, YOU MUST REPLACE THE SMART JUNCTION BOX/FUEL RELAY PANEL. THIS APPEARS TO BE A COMMON PROBLEM WITH NUMEROUS MENTIONS AND IS OFTEN DIFFICULT TO DIAGNOSE AND COMMONLY BECOMES A PROCESS OF ELIMINATION. THE BIGGEST CONCERN IS THE SAFETY ISSUE AND ODDS OF ACCIDENT OR FATALITY. DIAGNOSES TYPICALLY REQUIRES COMPLETE FAILURE BECAUSE THE SYMPTOMS CAN RARELY BE DUPLICATED. THIS HAS HAPPENED FREQUENTLY WITH COMPLETE FAILURE HAPPENING. HARDWIRING THE FUEL PUMP RULES THAT OUT. FUEL RELAY IS FOUND TO BE HOT TO THE TOUCH.