I have a 2004 F-150 with a 5.4, and it stalled out on me while I was driving it today and won't start.
I just bought the truck several months ago, and it started to idle rough after the engine would warm up (and sometimes stall out when I am stopped). It drives fine when I am giving it gas and doesn't show any issues in the first 10 minutes of driving it though, so I went ahead and changed the spark plugs, replaced the O2 sensors (all 4 of them), replaced the TPS sensor, and cleaned the throttle body, but nothing fixed the issue.

Even though it might be a separate issue, as I was driving it today it just quit on me altogether. It stalled out as I was driving at about 10 mph with my foot on the gas, which it has never done before. When I tried to start it back up, it sounds like it is trying to turn over but never does. I went ahead and took off the air filter box (along with disconnecting the MAF) and tried to play with the throttle body as my buddy tried to turn it over but still nothing. I waited around for 15 minutes and tried to start it again with the MAF sensor still disconnected, and I was able to start it. I kept my foot on the gas the entire time and was able to make it home. I disconnected the battery again to reset everything, put everything back together, and I started it again. I just left it in park for it to idle, and after about 10 minutes of running, it just stalled out again and won't start back up now.

You guys have any ideas of what this could be? Any help is appreciated.

 

Fuel Pump? I have had that happen on a different truck, and if I pounded on the tank it would kick the fuel pump in. Turn the key to the acc. position do you hear the hum of the fuel pump?

 

Yes, I hear the fuel pump. I checked out the fuel pump driver module and found that it was corroded and cracked. I brought it inside and let it air dry, reinstalled it, and it started right up again. Looks like I'll be joining the long list of people who need this part.

This still didn't fix my issue with the idle though. It still idles rough and stalls out after about 10 minutes of driving it when I am stopped. Any ideas why this is happening?

 

Not sure if it still may be the module causing the issue. But if all is good, might want to look at the fuel filter or something in the throttle body? I am sure some others may chime in with some additional help. I know my issue was the fuel pump.

 

Thanks for the input, and yea I'm hoping it's not the fuel pump itself so I don't have to drop the tank. I did replace the fuel filter as well with no luck in stopping the issue.

 

Any codes?

 

Nope, no codes. I do get an emissions light every once and a while, but that's it.

 

Anyone else have any other ideas? Could the cat cause this issue once it is heated up from running? Not sure if it would make a difference from cold to hot or not.

 

Still sounds like a fuel delivery problem to me, not the fuel pump then something in the line, injectors, etc.???

 

I haven't had mine stall out, but I finally gave up and brought it to the dealer tonight. I had the hard starting and rough running whether it was idling or travelling up the road at 55. I tried all the same fixes you mentioned with no luck. So I took it to a local service station and they couldn't find a thing wrong with it...so it's at the dealer now being checked out. I'll keep you posted on what they come back with...

 

We have a 2005 f150 with 175000 miles that 3 days ago stalled out while driving and then wouldn't start then and again a few days later. I looked on this forum, saw the suggestions about fuel pump driver module. We went on YouTube and saw how easy it was and subsequently replaced it. Truck started right up. Thanks for the help guys!

 

So have you actually replaced the FPDM (with a new one)?