last week truck (04 excursion, pre 2004.25 psd 6.0, 114k miles) wouldn't start in morning because of previous problems with bats i checked voltage first. it was okay but i still started the charging routine 12 hours then switch (two bats), 12 hours repeat for two days. weather was not so great so didn't get under hood till sunday morning, took bats to local parts store for load check and they are good. no codes, just "pass" but not starting. turns over but no fire - came here to start research. found info on ficm (mine is 7 pin) and did the start up voltage check and found 48v at KOEO but 26v when cranking. i'm not scared so i pulled it out and followed directions to re-flow solder on capacitors. total process took 20 minutes at my kitchen table (best light available) and the first 7 minutes was to heat up the iron. put it back together and when i tried to do the voltage check it started. tightend everything up and took it out for a 15 minute drive, all better - i was so proud of my self! next day drove it to work (only 1 mile away) then home, still no trouble back to normal. told my wife it's ready for her to take it back the next day, it's her kid runner and grocery getter. got a call at work around 10 am, truck won't start. same thing cranks - won't fire. got home today and still no codes and voltage at ficm test screw is good at koeo and cranking. whats next? sorry for the book form but i wanted to get all the info out in the first post, any questions? more important, any answers? help, what do you do when there are no codes?

 

What are you using to check codes? There is a no start thread to go through in the tech folder.

 

https://www.ford-trucks.com/forums/8...condition.html

 

i have followed that check list and came to the conclusion of fcim. once "fixed" and replaced i thought i was good. now same issue so i'm thinking chaffed wires but after visual insp and unplugging and re-plugging everything i've touched - still the same. one courious fact, when i turn over (after wait to start goes away) if i hold for about 3 seconds oil pressure on dash gauge shoots up and engine tries to fire but still no start. one time it started with real rough idle and black smoke ran for 15-20sec then stalled. this was before looking into wire chaffing now nothing. could egr, icp or anything else lead to this problem? i have checked fuel but not with pressure gauge. due for a oil and filters (gas & oil) change but within spec so probabaly not a factor.

 

actron scantool reader. basic scan/read/reset tool from ap store, $125 or so. nothing special but has code lookup and will read pid info. it did come up with a p0113 after trying to start (to test ficm) with air filter disconnected but i didn't mention that earlier.

 

po113 intake air temp high circut

because

open circut, or short to power

check intake air temp sensors one on intake manafold and one on the maf sensor

 

that code only showed up when trying to start with intake removed to access the ficm test screw. otherwise no fault code. mentioned it to show scan tool was working. no codes thrown when problem started. i know you can get to the fcim with only moving the coolant res but four more bolts on the battery tray gives you much more room to get in there (batteries are in garage on charger anyway).

 

Just because the FICM voltage is good doesn't mean the FICM is good. It can still fail internally and/or have loose connections that are very hard to see. Other things to check are ICP voltage to see if you are getting the necessary pressure to start.

 

last night i unplugged and re-plugged everything i've touched in the last 5 days. printed out chaffing wire locations list and tried to do a visual on all of those. all while batteries were on charger - it got late so inside i went. after work today i put the batts in to start the testing procedure again, begining with ficm voltage test and the thing started right up again. put it all back together and seems to run fine - back to normal? - no codes or check eng light. i have narrowed it down to chaffed wire i can't see but am moving, connecter not seated right (my favorite choice) or (worst choice) my ficm repair is not happy and causing intermitant trouble.

any other options from out there?

 

My 04 has done the same thing 3 different times in it's life and I never found anything definitive that I could narrow it down to other than "wiring".

If it does it again the DON"T disconnect the batteries if you can help it because that will clear any stored codes (if there are any). Try to get it to a dealer if you can to have it diagnosed from there. Electrical problems are hard to diagnose and harder to find sometimes. Harness problems were fairly common on the 03/04 vehicles.