Chasing a no-start for 2 days, it was a $4 relay under the fuse box all along
My 2003 F-150 left me stranded at a Lowe's in Tulsa and I pulled the fuel pump, swapped the crank sensor, even checked the PCM ground before a buddy pointed at the intermittent click coming from that rusty relay, two evenings of cussing for something I could have tested in 10 minutes with a multimeter, so has anyone else had a part that cheap hide behind that kind of basic symptom?
Something I could have tested in 10 minutes with a multimeter" is the part that gets me, because a relay isn't even really a multimeter job. You can just swap it with an identical one from the fuse box, like the horn relay or the AC relay, and see if the problem moves. Takes about 30 seconds and no tools. The click you heard was the relay trying to close, which points at the coil or the contacts, not the fuel pump circuit at all. Pulling the fuel pump on a 2003 F-150 for a no-start is a rough lesson. Been there with a main relay on an old Honda, same dumb feeling.