QUESTION: 2007 cheysler Sebring keeps melting ground terminal in fuel pump housing
ANSWER: Hi Rick, For a metal part to melt requires there to be either excessive current or too small a metal cross-section (and thus an abnormal resistance) in the conductor pathway such that overheating is produced. There are actually two black ground wires in the module on pins 1 and 4 of the module plug, one of which is related to the pump motor circuit and the other to the fuel level sensor circuit. I wonder whether the fuel pump may be faulty and is drawing too much current, or there is excessive resistance in the socket- or harness plug-side of the module's electrical connector. You didn't tell me any history about this problem so I don't know any other details about your problem. But a person with a volt-ohm-amp meter should be able to make measurements at the connector to ascertain which of the possibilies is at work (excessive current/excessive resistance). If you can tell me more details I may have an idea as to what to try next. This fuel pump module and associated circuit was new for the '07 model so there may be a factory service bulletin on the subject that a Chrysler dealer would have on file. You could report this to the Corporation as a safety hazard It is probably not a good situation to have a heat source capable of melting metal located in the fuel tank. Please 'rate' my answer (see below). Thanks, Roland
I did find the following 'complaint' filed at AboutAutomibile.com Evidentally someone else experienced the same failure:
Complaint Number: 10429623
Incident Date: October 9, 2011
Date Added to File: October 12, 2011
Description of the Complaint: The contact owns a 2007 chrysler sebring. While driving approximately 30 mph the engine stalled without warning. The engine restarted and the failure occurred continually while driving. The contact stated the fuel pump electrical connector and the fuel pump body melted. The diagnosed or repaired. The manufacturer was not made aware of the problem. The approximate failure mileage was 62,000.
I would check out the plug and socket where the melting is occuring to see if it may have excessive internal resistance on one of the two ground wire contacts.
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QUESTION: Installed new pump and connector and same problem occurred approximately 2,200 miles after I did the repair.
Hi Rick, About all I can suggest is that you measure the resistance to ground of the two ground wires on the connector to be sure that you have as close to 0 ohms as you can get, if indeed the melting is occuring at one of the ground lead connection points. It has to be too much current is being carried or there is a low, but nonetheless finite resistance at the connector that is causing the connector to heat up. You might want to change the ground wires from the connector to chassis ground point nearby with a thicker gauge of wire. And you might want to file a complaint with the National Highway Traffic Safety Administration in Washington so as to establish a file for others like yourself who are experiencing this issue. It would seem to me to be a hazard that should be addressed by Chrysler Corp. Also file a report with www.AboutAutomobile.com to add to the other item just like yours on a 2007 Sebring. Roland