hi everyone. i have a 2002 ford ranger 4.0L. last week it almost blew up because there was fire at the fuel pump pigtail/wiring harness connection. ford does not carry the main wiring harness at the frame. does anyone know where i can order a new or aftermarket one or do i have to get matching colored wires and make a new harness?

 

Welcome to the forum

Wrecking yards would be best bet

But I would first find out why fuses didn't cut power to fuel pump, its the only higher amp wire back there, only one that could even remotely start a fire by melting a wire
Fuel pump power fuse is in engine bay fuse box, in 2002 its #23, 20amp

Fuel gauge is a Pulsed 5volt
All sensors anywhere are 5volt

Check if previous owner may have run a 12v power wire for used in the bed and didn't fuse it correctly at the 12volt source(battery)


1998 and up Rangers or Mazda B-series should be the same wiring harness at the tank
7 wires at top of fuel tank
3 are for the pressure sensor, brown/white, grey/red. red/pink wire colors

1 12v wire for fuel pump, pink/black stripe wire
1 Ground for fuel pump, black/yellow stripe

1 5volt wire for fuel level sender, yellow/white stripe
1 ground for sender, black

 

Thank you RonD for the info. I forgot that ford and mazda share the same truck in one way or another. Ill check with mazda and see what they have. Ill check all my grounding straps as well. This truck has been giving me grief and ive been trying to figure it out. Hopefully its something simple and i hope it didnt get damaged beyond repair. New fuel pump has been ordered.

 

I also noticed that mine has 4 wires in the pigtail on the fuel pump. Is it possible for a wire in the harness to break and cause a short? Ive noticed some missing while driving. Its feels like a hiccup then it resumes like everything is okay.

 

Yes, fuel pump plug only has the 4 wires, 2 grounds, a 12v and a 5v wire
Sensor is another plug on the top of tank, with the 3 wires

The fuel pump wire, pink one, has a 20amp fuse that would blow, before the wire could melt
So can't see that happening
Only other thing would be a 3rd party wire, from previous owner

Yes, if fuel pump power was cutting out then engine would stumble at that time, like running out of gas, because that is what's happening

 

thank you for your reply RonD. I looked at the pigtail to harness connectors and they are fried on the side that clips to the frame of the truck. i cant even seperate the connectors because they are melted together a little bit. im going to remove the bed of the truck this weekend to get a top down view of the harness and peeling it back enough to see the wires. if any are burnt, ill get a harness repair kit and cut and splice the bad wiring. i will also be looking at all the grounds. i did notice that my horn isnt working right either. when i use the remote to lock and arm the system, the horn is supposed to give a short honk. now it sounds like someone shoved a sock in it and it is muffled. not sure if that has anything to do with the fuel problem or not but it could be a red flag.

 

Those connectors are available online but it does take some intensive searching to find them. They're typically not cheap either.



GB :)