5.4L 2003 Ford Excursion XL stalling/shuts off or dies at random times

sounds like fuel relay issue. the key is in the on position and so we already know that fuel pump is working and getting fuel to block. there was no reason whatsoever to buy that pump because the pump has already been activated when the key was in on position in the key spindle. BUT now that it died again with new pump, kind of makes you feel silly, right? nonsense. Change the fuel relay and then I'd take that shop to small claims. There's no sense in having them change it back out when they will just break something else. keep your chin up

My 2004 Excursion just started having the same problem with random stalling. Did replacing the fuel relay fix the issue?

I also have a 2005 Excursion with a stalling problem. After 3 trips to a local mechanic, they were finally able to reproduce the problem. They tracked it down to the circuit board that is next to the fuse panel. The board has micro cracks and will fail when the vehicle is too warm. It happens more often in warm weather and when you are running the vehicle hard (ie hot). Mechanic had a difficult time finding the board, but finally found one at a junk yard. Problem solved.

There might be a wiring problem. Either shorting to another wire (like a reference voltage wire) or to ground. Who knows!? I have a 2002 Excursion that would often die when you put it in reverse (got worse and worse until it was almost a constant problem) but when I wired up a bypass power wire from the battery to the MAP sensor power wire (feeds back to provide power to various sensors in all likelihood). After doing that, the problem went away (runs okay in reverse) but I have to manually disconnect the wire when I am not using the truck to save it from battery drain.

It’s Fuel pump relay. Its located on the back of fuse box under the steering wheel. Once you change it you shouldn’t have any problems. Don’t waste your time trying anything else.