Ibro Cehic
Updated on September 23, 2022
Every car manufacturer makes a mistake once in a while, and one of Ford’s errors was the design of the early fuel pump modules. Luckily, a Ford fuel pump module bypass is an easy job, and it doesn’t cost to replace them.
To bypass a Ford fuel pump driver module (FPDM), you must first locate it on your vehicle. Unplug the FPDM and hard wire the ground and fuel pump ground wires on the connector. After that, do the same for the 12v power supply and 12v fuel pump wires, and you have bypassed the Ford fuel pump driver module.
That said, unless you have some experience with wiring, you will need a little more information than this. So, here is everything you need to know about the fuel pump driver module and how to bypass one.
What Is a Ford Fuel Pump Driver Module (FPDM) & How It Works
The fuel pump driver module regulates your vehicle’s fuel pressure. These modules are a somewhat modern system employed by Ford for the first time with the 1999 Mustang.
However, the eleventh generation F-Series trucks, which came out in 2004, are the Ford model that made these modules famous. That’s because they were a common problem in the F-Series. We will go into the reason why shortly.
How Does a Ford Fuel Pump Driver Module Work
Instead of the FPDM, older cars used a fuel pressure regulator. The fuel pump would continuously provide a higher pressure than needed in such a system. And to keep everything in check, a fuel pressure regulator (FPR) mounts on the end of the fuel rail.
The FPR would open to varying degrees depending on the fuel pressure. Once it opens, the excess fuel returns to the fuel tank. That means an FPR constantly changes its valve position to regulate the pressure at all times.
The reason why Ford and other manufacturers turned to a more complex system instead of a simple mechanical spring-loaded valve wasn’t to get more money out of its customers.
The fuel pump driver module allows the PCM (Power-Train Control Module) much more control over the fuel pressure.
The FPDM controls fuel pressure by continuously switching the fuel pump on and off. The higher the switching frequency, the higher the fuel pressure, and vice versa.
Furthermore, the FPDM system doesn’t need a fuel return line like the cars with an FPR valve. Because of that, the FPDM eliminates much of the fuel evaporation.
That’s why such a fuel system is also called “returnless.” The result of all this is a much more efficient engine that doesn’t waste as much fuel.
Why Do Ford Fuel Pressure Driver Modules Fail
Fuel pressure driver modules have been problematic ever since they came out. The early ones from the nineties had a lot of overheating issues because manufacturers mounted them in the cabin under the carpet.
When Ford started implementing them in its diesel trucks, it decided to put them outside the vehicle, close to the fuel pump. While mounting them on the exterior and using more modern technology solved the overheating, it also created other problems.
The housing of the fuel pump modules was aluminum, and Ford mounted them directly on the truck’s steel frame.
Now, the problem is apparent for those who have some knowledge of chemistry or the technology of materials. Steel and aluminum don’t go well together because aluminum will quickly deteriorate in such an assembly.
That process is called galvanic corrosion. When these two materials are in contact, aluminum transfers electrons onto the steel, weakening it to the point of creating holes in the material.
Since the FPDM is an electronic assembly, it would easily short its circuit and leave you by the side of the road without warning.
But, if that happens, you don’t necessarily have to call for a tow truck. Bypassing the FPDM is relatively simple, and once you do, you can drive your vehicle to the closest repair shop or home.
Replacing Ford Fuel Pump Driver Module (FPDM)
Ford has solved the corrosion issues with the new OEM fuel pressure driver modules. That means if you need to replace your FPDM, the kit now comes with new distance bolts.
These bolts separate the aluminum module housing from the steel frame. With that, they eliminate the cause of corrosion while keeping the same mounting location.
If you are reading this and your FPDM is still in good working condition, you can also improvise these bolts without buying a new module. You will only need longer bolts with a half-inch-long plastic washer or something similar to fit under the module.
Diagnosing a Ford Fuel Pump Driver Module (FPDM)
Unfortunately, the FPDM won’t show any warning signs that it’s on its way out. If your truck has shut down while driving or won’t start, but the engine cranks over, it’s best to scan the fault codes.
After that, if you get a P1233, P1237, or P0191, it usually indicates a faulty FPDM. Here is what to do for each of the fault codes.
Fault Code P1237
A fault code P1237 means a problem with the secondary fuel pump circuit. A few things can cause that, but in any case, your truck probably isn’t moving until you solve it.
You should first check the fuel cut-off/roll-over switch, which can sometimes go out for no apparent reason. The location of that switch will vary depending on the vehicle model, but you can always check your car’s manual.
Once you find it, the big red button should be down; if it’s not, make sure it is. However, if that doesn’t solve anything, the best thing you can do is check if the fuel pump is working.
For that, you need to bypass the FPDM, which we will explain how to do later in this article. Once you bypass the FPDM, if the truck starts, the FPDM has failed. If it still doesn’t start, the fuel pump is dead.
Fault Code P1233
A fault code P1233 means the fuel system is disabled or the fuel pump driver module is offline.
If you get this code, like before, you should inspect the fuel cut-off switch first. If that checks out, it usually means the FPDM fuse is blown.
The main reason why that happens is because of a short circuit—a short circuit caused by corrosion of the FPDM housing. The only solution is to replace the fuel pump driver module or bypass it until you get a new one.
Fault Code P0191
The fault code P0191 means indicates low fuel pressure. More often than not, it means the FPDM is faulty. However, it can also mean the fuel pressure sensor is bad. The best you can do is have someone check the fuel pressure.
If the fuel pressure is good, the fuel pressure sensor is faulty. If the fuel pressure is, in fact, low, the FPDM needs replacing.
How to Bypass the Ford Fuel Pump Driver Module
To bypass an FPDM, you must first find it on your vehicle. On a Ford Expedition and F-150, it’s usually on the subframe in front of the rear wheels.
Although it’s on the outside in most cases, in a Ford Focus, for example, it’s under the rear seats. If none of these is your model, it’s best if you do a quick google search or consult a manual to find it.
Besides that, the FPDM connectors can also differ, but the process is the same. However, it would be best if you had the connector diagram to know which terminals to hard-wire. But if either of the following connectors matches yours, then there is no need to look any further.
Before we explain how to do it, it’s important to note that driving a vehicle for a longer period with a bypassed FPDM can cause further damage. It’s not a problem if you do this to take your car home or to a repair shop, but make sure it’s not longer than 20-30 miles.
The Tools You Need
- Something to strip wire insulation (utility knife/scalpel or pliers, for example)
- Two pieces of wire
- Flat screwdriver (to help you unplug the connector)
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How to Bypass an FPDM
- Disconnect the connector
- Make two pieces of wire about two inches long and strip the ends
- With one wire, connect the pins in red color with each other (refer to the picture below)
- With the other wire, connect the pins in the green color with each other
- Make sure it’s a tight fit so they don’t slip out while driving
Ford 2004-2008 FPDM Connector Bypass Diagram
Ford 2009-2014 FPDM Connector Bypass Diagram
FAQs
How Much Does It Cost to Replace a Fuel Pump Control Module?
The fuel pump module alone can cost anywhere between 60$ and 250$. Labor also varies depending on the vehicle and can set you back between 100 to 600 bucks. Ford FPDMs are on the lower end, with the price starting at 85$ for the part and around 100$ for labor.
What Common Troubles the Fuel System Can Have?
The most common fuel system problems are fuel injectors, fuel filters, fuel lines and hoses, and the fuel pump. Other issues can include wrong fuel, fuel pressure regulator or sensor, fuel tank corrosion, and electronic issues.
How Do You Test a Ford Fuel Pump?
If you want to check the flow of the fuel pump, first take the fuel pump fuse out. After that, disconnect the fuel pump “out” hose and place it in a container, so the fuel doesn’t spill.
Next, put the fuse back in and turn the ignition on. Allow the fuel pump to run for about 10 seconds and turn it off. After 10 seconds, it should pump about 500ml of fuel.
How Do You Unclog a Fuel Injector?
You can try to unclog a fuel injector using fuel injector cleaners. If that doesn’t help, remove them and send them to a professional for testing and cleaning.
How Do You Tell If Your Fuel Pump or Fuel Filter Is Bad?
The main symptoms of a bad fuel pump are poor acceleration, decreased gas mileage, difficulty starting the car, and sputtering. The main symptoms of a bad fuel filter are engine stalling, fuel pump noise, engine misfire, and a rough idle.
What Are the Symptoms of a Faulty Fuel Pressure Regulator?
Some symptoms of a faulty FPR are smoke coming out the exhaust, rough idling, stalling, and difficulty starting the vehicle.
Fuel pressure regulators rarely have to be serviced and can last hundreds of thousands of miles. To avoid any issues with the FPR, you should change your fuel filter roughly every 25,000 miles.
Conclusion
Unlike most other car issues, the fuel pump driver module won’t show any symptoms of failing until it stops working. And, when it does fail, your only solution is to get a tow truck unless you know how to bypass it.
Luckily as we have seen, bypassing one is very easy once you see the connector diagrams. It also helps that you only need a piece of wire and can improvise everything else in the worst-case scenario.
All you have to do is refer to the diagram, connect the correct pins, and save yourself a lot of time and money. In the end, remember that this is only a temporary solution, and you need to replace the fuel pump driver module as soon as possible.
For more related Ford topics, here are our other posts:
How to Reset the Ford Blend Door Actuator
How to Bypass Ford Pats System Without a Key
What Does Ford Say About Catch Cans?
