For about the last year my Expedition has this random cutting out while driving. It doesn't stall, just cuts out for a second but it's random. Sometimes it may do this 5 times in one trip, other times it won't do it at all. no CEL and it's been driving me nuts.

So last week I went to start her up & it wouldn't fire, just cranked for about 15 seconds & then fired. I figured I'd plug the OBD2 code reader in & see if anything could be stored. There was one code which was for the PATS key.

So I got to thinking, I cleared the code & switched keys with my wife. My key must be going bad because it doesn't do it with her OEM key. The other was a key I had cut/programmed about 5 years ago. Guess it's time to make another one.

Maybe this will help someone with the same issue.

 

There have been others in the past that have had the no start issue with the correct keys but that was due to having a lot of keys on the key ring and the PATs signal was interupted by them as they blocked the signal from the code reader. I suggest that you swap keys with your wife and see if the issues go with the key or stays with you and your key ring.
The momentary cutting out has been traced to the ECM connection located in the firewall being loose due to not being tightened all the way.