It's a starting point at least.

IIRC, Another member did this a short while back on one of their relays that was causing a problem:
Check the blades where the relay plugs into for any sign of corrosion/rust/dust build up. Clean it as best you can.
Bit of electrical spray to give a little extra cleaning.
If, when you plug the relay back in, it slips in easily, take it back out, use a small screwdriver and CAREFULLY bend the tangs in the relay board in a little to make a tighter connection when plugging the relay back in.
For what they cost, replacing the relay for a new one wouldn't hurt either.

If indeed this is the problem at all.

 

Very interesting, and some great troubleshooting. Had you tried to start the car (unsuccessfully) just before reseating the relay? Or did you fiddle with the relay first? If the former, that would sure point to something you did, whether the relay itself is bad or the connections were at fault.

For giggles, try popping off the cover on the suspect relay. Look for any signs of arcing like on this one:

 

yep, I did try to start the car prior to messing with the relay, so I think the relay is a strong suspect. The car starts right up for now, so I'm going to drive it for a few days to see if it gives more issues. I may have the dealership order me one up just to have on standby . On another note, it started first try once again this morning. since I have fiddled with the relay, there have been no starting issues. so far so good .

 

Little bit of an update, After the past two days, the issue only happened once more and I immediately removed and reseated the relay and the car started right back up. Today I went to the Ford dealer and picked up a new one for 18 dollars. I put it in and the car started with no issue. I decided to take the old one apart and could see no arc'ing but the thing was EXTREMELY hot... I guess time will tell. As I was driving back from the Ford dealer, I was wondering if there could be something connected to the relay that is causing it to fail. I don't want to get ahead of myself but just trying to think of other things in case this is just a symptom of something else .

 

See if the new one is similarly hot.

 

The $64 question:

Did the new one get hot?

This thread talks about (hopefully) normal temperatures for relays in use:


https://www.jaguarforums.com/forum/s...-r-s-c-187819/

 

Yes, your fuel pump. There will come a time, probably sooner than later, when a new relay will not solve the problem. Your fuel pump is screaming, "I'm dying in here!"

 

For peace of mind, you could test the amp draw of the fuel pump. The easiest way to do it would be at the relay socket.

 

ok, so the new relay seems better heat wise, but I'm not going to pop the top off to do a closer look. I'm going to ride it until it bucks and start saving some money for a new rule pump. looks like Rockauto is out of the pump for now anyway. as always, tons of fun..