Not your normal fuel electrical question

[desertdog]

Yesterday my fuel pump went out on my 93 Vert.This was the replacement for a fuel pump I replaced in July.The pump I put in was from the Ford Dealership and was a direct replacement for the car.When I pulled the pump out the insulation on the live wire was burnt for about two inches from the top of the bracket down.This is about the same thing that happened back in July.My quetion is;Is this what is suppose to happen when a pump goes or is it a sign of an electical demon somewhere in the electrical system.My car is essentially stock,I don't really pound on it,so this has me stumpped.Thanks for all the great advise that you have given to me in the past,because it only took me about a half hour to take the gas tank down yesterday-of course I just did it back in july.
Jim
As a side note the guy at the parts counter said he didn't have a clue,but replaced the pump,no questions asked.

 

[ss93cobra]

Sounds like a poor connection to me. There are some companies out there that sell a replacement pigtail for these cars. In fact, I work at a Ford dealer in IN and we have them, are you in IL at the moment? The chances of you having 2 defective pumps in a few months time is next to impossible. Not exactly sure how else to explain it, but its definitely an issue of resistance.

 

[desertdog]

Sounds like a poor connection to me. There are some companies out there that sell a replacement pigtail for these cars. In fact, I work at a Ford dealer in IN and we have them, are you in IL at the moment? The chances of you having 2 defective pumps in a few months time is next to impossible. Not exactly sure how else to explain it, but its definitely an issue of resistance.

Yep-Downers Grove to be exact.I did replace the pig tail on top of the tank in july because it was burnt and warped.In july I also replaced the live wire because it was roasted(the insulation had disappeared and the wire was black).Currently I may have to replace the fuel bracket itself because the insulating pad(on the internal side) between the connector and the top of the tank is burnt and part of it has disappeared.The wire connection,between the wire connector and the post, is also very loose.This wasn't the case in July or I would have adressed the problem then.I just don't want to run into these problems and I do think that blowing a pup in 3-4 months would be rare,that's why I threw this post up.Thanks for the quick response Cobra
Jim

 

[ss93cobra]

If you got the pump from the Ford dealer it should have been the complete assemby anyway, which means the ENTIRE thing should be new. So, the connector was new, as well as the complete assembly? To burn the insulator pad was pretty strange. The connector being loose inside would cause the burn too as it was arcing around. Good luck to you.

 

[tmoss]

Yeah, you had a loose connection - heat builds up and causes the insulation to get brittle and crack off as well as discoloring the copper wire. If you get tired of doing this, solder the wire to the pump connection male spade.

 

[JB66]

I tend to agree with all these. Wires overheat because of excessive amperage being run through them. Amperage increases when either of two things happen. #1 is when resistance is too high. This could result from a loose connection as has been suggested. Don't stop at the tank connection, though. Check ALL related connections. #2 is when voltage is too low. Use a voltmeter and check the voltage at the pump connector both off and with the pump running. Again, a loose connection can cause an excessive voltage drop to the pump. My vote is for #2.