Hi,
My 03 Eddie Bauer Expedition 5.4L has an intermittent problem. It cuts off sometimes when you are driving down the road. It will then just turn but won't start, I have found that if you unhook the battery cable and then try to start it, it starts up fine. Sometimes, when it does this it will work fine for months/weeks and then other times that will only get you a few miles down the road and it does it again. It throws no codes, so a scanner does no good. We have had the crank sensor changed and also the alternator cable because it wore through from rubbing an a/c line. Don't want to throw a lot of money trying to chase this problem, but getting tired of being stranded along the side of the road with just me and my son.
Please help.

 

Sounds like a bad ECM to me.

 

Ugh, the ECM really?

I was thinking that it was fuel related. Oh well....I guess I will order an ECM. Thanks.

 

Check it out further, I'm not there you are. At least test the fuel pressure first before ordering an ECM.

 

I would go to the PCM only as a LAST resort, only AFTER eliminating everything else. The PCM doesn't fail very often, they are extremely reliable.

If you reach the point where PCM replacement is positiviely indicated, be aware that replacing the PCM isn't a simple DIY project. You will need to have the anti-theft (PATS) system reprogrammed at the time the new PCM is installed, otherwise the security system will prevent the engine from starting. Tat means a Ford technician, a competent locksmith, or a well-equipped independent technician is going to have to be on hand when the replacement is installed, otherwise, the truck isn't going to drive anywhere with the new PCM installed but unprogrammed.

Personally, I'd throw a new PCM power relay in there first since there isn't any real data and only sketchy observations. They're cheap and easy to install.

 

I did alittle bit of research on my own and found a couple of threads that sounded exactly like what has been going on with my car. I think I'll try what they came up with and hope and pray that that fixes it.

 

Ended up being the fuse box. Changed it out and all is well. Took old one apart and had burnt relay

 

To me this is such a bad design when instead it's so simple to have a relay socket allowing easy replacement of the relay.