Repair 2003 Lincoln Navigator Expedition internal fuel relay bypass

[@CtDDtC1919]

A friend of mine had taken her navigator to a couple of different mechanics and they couldn't figure out the problem. The last one swapped out the fuel pump, and it was still stalling and not starting at random intervals. She told them it had to be the fuel pump relay. They blew her off. One said they swapped it out for a good one and it was still having problems. I told, and showed her that the fuel pump relay is nonservice-able. She asked me to do the work. I followed your advice and it solved the problem. Thank you for this video!! One VERY important thing that I want to stress to anyone doing this fix: It bypasses the RPM sensor/control. I HIGHLY advise putting in an inertia switch in series between the power applied from the key function to the new relay. If you do not, and there is a collision or rollover, the pump will continue to pump gasoline, and create a hazardous condition. The inertia switches are inexpensive, and it is an easy modification/safety measure.

[@lightningsanchez5312]

Can you show us please

[@CtDDtC1919]

@@lightningsanchez5312 Sorry, I keep trying to give you my email, but it keeps being blocked. If Earthling Art wants, I have a very easy to understand image that shows all connections and details of the WHOLE project, that he is welcome to add to the end of his video. Not sure how else I can help. Except to say, add your inertia switch in line with the switched power line, and mount it securely to the frame so that it picks up any heavy impact. I like mine in the engine compartment so I can easily reset it if it triggers while off-roading.

[@sheltermutts4185]

Thank you. I was ready to throw away my Lincoln. But I have a spare relay laying around and I can do this!

[@brandonhutchins7976]

Is the harness plugged back in? I have a 04. It was previously by passed but they have it a little different. I’m trying to find out why it’s set up different.

[@angelbush6692]

What all did you use

[@1785johnson]

Great video just got a new subscriber I have 05 Lincoln navigator same problem what are all the tools/devices use in this video?? I’m trying to do it the exact same way

[@rubio7922]

Does this keep using the inertia switch like normal or does it bypass it as well?

[@antoncgi]

It does not bypass the inertia switch. That would be pretty dangerous.

[@antvit697]

In my 2004 expedition i dropped the tank because the fuel pump was not working after i had the pump out i tested the plug and was getting power but no ground.. The fuel pump worked when i bench tested it but not when i plugged it in.. Any suggestions? Im assuming its not getting ground..

[@antoncgi]

drive.google.com/file/d/1FvDACRZMMu7a5BBlDc-CtBpU_RFEsJll/view?usp=drivesdk

[@antoncgi]

This is the diagram I pulled for a 2004 with a 5.4. If you look at the lower right it shows ground doesn't have far to go to the pillar. Anywhere on the frame can be a good ground if you polish it a bit.

[@antvit697]

@@antoncgi its what i kinda figured.. Appreciate it

[@Tibbs1904]

I'm sry if this is a dumb question but what size relay did you use I know you said it was a 5 pin but is it a mini or micro or what?

[@Tibbs1904]

What's the color of the one you put your switch to

[@ajsquad1042]

Can I get a clear pic of that relay switch with voltage please

[@antoncgi]

Yeah so that was a standard 5 prong 30amp 12v relay. They usually have a diagram on them that shows how they work. The coil is usually powered by terminal 85 and 86. Terminal 30 connects to the center terminal 87a when the coil is powered. All voltages are 12v.

[@antoncgi]

shop.advanceautoparts.com/p/dorman-conduct-tite-30-amp-12-volt-5-pin-universal-relay-88069/11223721-p?product_channel=local&store=4667&adtype=pla&product_channel=local&store_code=4667&gclid=CjwKCAiAtouOBhA6EiwA2nLKH-h8_PQ0BjLii7svWKBd_rlzQy8xd5LjcDDmzJ0GesRuJyQYRZl3jhoCveEQAvD_BwE&gclsrc=aw.ds

[@antoncgi]

You can see an example of one at this link here

[@rubio7922]

Looks exactly like my truck lol.. If you could message me the exact wires you connected to that would be awesome.. I tested on the board and the plug gives me only 6.3 volts when key is turned. So I'm sure it's the fuse box.

[@mikimiki195]

This could have been good video if you explains what wire corespondents to what color and number also gauge wire is important. Thanks

[@antoncgi]

I'll take that into consideration. Are you asking me for this information for your application?

[@mikimiki195]

@@antoncgi No I got my figured But if you look at similar videos they have 1000s of 👍🏻 and 100s of comments Good luck

[@ryand5041]

14 gauge

[@travisbarrett9398]

Hey where you from I need that exact thing dun to my truck

[@antoncgi]

I'm just outside of Portland. You'll probably need to just show this to someone closer : )

[@calitosanto4343]

Good video

[@angelbush6692]

What all did you use