The fuse never really popped, rather the aluminum part that wraps around the plastic fuse melted and pulled away from the contacts.
You can see where it did actually take out a little bit of the female connector in the fuse box, so it's possible we will have to repair this with the fuse relocation kit. usually have some heat after running for prolonged periods. not so much the solid state stuff, but blower motors, fuel pumps ect. You always see brown contacts on fuses and connections that draw power for higher amp motors and such. These new fuses wouldn't need much to melt given their new design. It would seem the aluminum that is the contacts for the sides of the fuses is really very thin and just folded around the plastic of the fuse. So if it does come back in on short order I will re-post to this thread with details about the kit for relocating the fuse and or any other problems I found. In situations like this we charge a standard diagnosis fee that is later applied to any work relating to the same inspection. I also sent him with the pack of fuses incase it happened again. I didn't have access to the dealership parts department to get a relocation kit however I did replace the fuse and everything was fine again. In any case, I thought of PowerStroker in this instance, figured he must have seen this before and if so - what his thoughts were. Some are saying it could be the module under the tire, some say (myself included) that a wearing pump could be contributing to it, others are saying (myself included) that the gauge of the connection for this type of circuit may be too small to transfer the heat. I only say this because this seems to be a well known issue with this particular year and model of F150 I have no doubts that a bigger surface and connector area of a maxi fuse would have prevented this problem. Of course the pump could be drawing more amps at it's age of just 220+k miles, and one would have thought a maxi fuse would have been used on such a circuit, however given the fact it is the fuel pump, it's possible they were just being abundantly cautious. Reading up on the issue I gather that Fords has made a fuse relocation kit for this in the instance it melts all the way down and the contacts are missing.įrom my years of experience, I would imagine the load of this circuit (fuel pump) is such that the heat and such relative small size of these newer maxi fuses and their contacts, that over time it just melts them away from the heat. Upon replacing fuse #27 in the engine compartment fuse box (just above the radiator) the truck runs fine now. Come to find out fuse number #27 was burn up, looked like prolonged exposure to heat. Had customer get towed in today on a no-start 2010 F150 4X4 with the 5.4 liter engine.
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