fishing for help and keeping my fingers crossed.

I got in my truck this morning (2004 super duty w/6.0ltr) and started the truck without any problems. Once the truck started I got out as I was going to let it warm up. I closed the door and locked it with the door lock remote and started to walk away. I got about 2 steps away from the door and the truck shut off just as though somebody had actually turned off the key. I tried to get back in the truck but the remote for the door locks wouldn't work nor would the keyless entry. I used the spare key to open the door and there was no electrical anywhere, everything was completely dead. I turned the key to the off position and and heard a rapid clicking sound coming from behind the fuse panel.

I'm thinking it has to be a fuse of some sort but what fuse would kill everything?
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Coming off of the driver side battery is a heavy red wire. This wire goes forward to the Central Juction Box under the dash. Somewhere in that line are two 12 gauge fusible links. All of the power for the truck except the main power to the Glow Plug Control Module and the heavy power wire to the starter go through that wire and those links.

I'll attach the wiring diagram but it doesn't really do much to help identify where those links are. I think I'd start by pulling the CJB down (about 4 bolts) and seeing if you can find power on that main input.

If it is the fusible links, the big question is what caused them to go.

 

According to the book, S1002 (splice 1002) is "Wiring harness - Battery output (14300) near grommet, engine bulkhead." S1000 is "Wiring harness - Battery output (14300) in T/O to Junction block, left fender." I don't know what a "T/O" is.

On my truck, that big red wire disappears into a wiring bundle about 2 inches thick that heads for the firewall. I can't see where it goes through, there is too much stuff in the way.

 

I went out to check the fusible links but decided to first see if I could figure out where the rapid clicking sound was coming from under the steering wheel. while I was manuevering myself under the dash (key's were in the ignition) the door chime went off to remind me the keys were in the ignition. I jiggled the ignition cylinder and the gauges flickered for a brief second.

I think this would suggest that there is power getting somewhere.

the other odd thing is that the rapid clicking (sounds like an electrical contact opening and closing in rapid succession) stopped when I stepped on the brake pedal to see if there was power going to the brake lights.

fyi no power to horn or brake lights.

 

Wow. I don't have a clue.

Jiggling the ignition causing the gauges to flicker might lead you to believe there was a problem in the ignition switch or column somewhere. But that would not cause the brake lights and the horn to fail, since those are powered Hot at all times right from the CJB and don't go anywhere near the column.

I think the problem has to be in the CJB, but I don't know what it could be.

 

my thoughts too!!!

its a head scratcher that I think is going to have to be left to the dealership to figure out.

 

thank you for the help and direction. I appreciate having a fresh perspective.

 

This may be oversimplified but........Whats the chance the batteries just froze considering where u live? The alternator would not have kicked in yet in the short period of time you described so if the batteries developed an issue and died, the truck would have cut off.

 

admittedly I have not checked the batteries simply based on the sudden onset of the issues. There is no harm in checking the batteries though so I will do that tonight when I get home from work.

I did have a problem last week when my son unplugged my truck to use the extension cord and then never plugged the block heater back in. Fortunately after a few hours of being plugged in the truck fired right up without any problem. It has warmed up considerably since then and I haven't needed to plug the truck in at all for the last number of days as we have been above freezing. There hasn't been any signs of weak batteries and even the one day the truck froze up on me I still had lots of cranking power just no fire because everything was too cold and I couldn't get the cylinders warmed up enough to fire.

I don't think the batteries are the problem but as I said there is no harm in checking.

I do have a little more information though. last night as I was under the dash again looking for a short or something I had the drivers door open and as I was rummaging around in the mass of wire bundles routed through the area suddenly my dome light and my door chime came on. I put the key's in to try to start it but as soon as I touched the brake everything died again.

this is starting to look like one of those phantom electrical problems fords are prone to having.

 

update:
took one last look around before I shipped it off to the dealership. traced the power wire back to the fusible links and found a lose connection. Tightened it up and everything is fine, so all and all were good.

thanks for your help everyone