Ford Repair Questions? Ask a Mechanic for Answers ASAP
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It can be caused by several things. The most common is the switch and connector itself develops high resistance causing the heat. I have replaced countless switches and pigtail connectors on rangers. The second most common would be the fuel pump wearing. The additional drag of the pump impeller increases the current draw on the circuit and the inertia switch is the weak point. Restricted fuel filters can also cause the pump to draw more current. If it were mine I would replace the switch and pigtail connector with OEM parts available from a Ford dealer.
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