2003 5.4 Expedition Relay Panel
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Mountain Pass
Joined: May 2004
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2003 5.4 Expedition Relay Panel
I have an issue where the relay switch melted and I have gone through 2 relay switches, now the panel has slightly melted. Not sure why the switches are heating up and then burning out. But when I turn the key I hear a buzzing sound coming from the kick panel, at first I moved the relay switches around and then it started and was good for about 2 months then it started doing it again (buzzing when I turned the key) so I bought all new relay switches and we were good for the last 2 months and it has now started doing the buzzing again. I am looking at replacing the whole relay panel. (due to the slight melting, I don't think that the relay switch is making good contact) Can anyone give some insight as to what the issue maybe, could there be a ground? I have an after market remote start system (has been installed for over 4 years and have just started having this issue about 5 months ago) Thank you for any tips or guidance may be able to give.)
Fleet Owner
Joined: Apr 2008
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There's only 2 reasons for this. One is bad connections creating excessive heat. Second is more power being pulled through the contacts than they're rated for.
New User
Joined: May 2013
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Reading some postings I believe this might be an issue with my 2003 expedition. Just over the last week it has cut out a few times even while driving. It starts straight back up and without any error message. I changed out the fuel filter a couple of days ago, but it happened again today. Is there a way to confirm that the fuse panel is the issue? I have not inspected that yet, hopefully my wife can make it home from work to do so.
New User
Joined: May 2013
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Not the fuse box - it was a bad battery and pcv hose
My problem turned out to be the battery. This can affect several things and create random symptoms when it is going bad with the numerous on board systems. Thankfully a new one has done the trick so far. I did also notice when installing the new battery, that the pcv valve hose had a hole, I also changed that out. Per my local Ford dealership, the fuse issue only happens in parts of the country with heavier rainfall. Hope this helps, I was in the process of tracking down a new fuse box$$$$$
Freshman User
Joined: Jun 2013
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I know what you mean! I tried replacing my battery, charged my battery twice, replaced the relay solenoid for the starter, replaced my starter 3 times, had to replace my solenoid wire that runs from the relay to the solenoid, and now I am at the process of my fuse boxes are not reading. If only I would have checked the most basic of things like the fuse box first!!! I am so mad at myself for this! It has rained and I think this could be the issue with the windshield leaking. Last night I attempted to take out the fuse panel under the driver side compartment. Of course I have to wait late in the day because I live in Texas and boy its hot!!! Plus no garage. 
It has been 3 months and I just need to get this fixed already!!!!
It has been 3 months and I just need to get this fixed already!!!!
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New User
Joined: May 2013
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Interior Fuse Panel
That is brutal!!! The fuse panel I was reading about is on the passenger side (2003 Expedition) and apparently it is not serviceable, or at least most of it. Perhaps there are fuses both sides? Anyway I hope it is something simple (cheaper) for you to fix. I came across a number to a wrecking yard for Expeditions here in CA at 818-767-0316. They had the parts at the time and just needed the part number to make sure it was right, and will mail it. Then I figured out the battery/pcv issue and never got beyond the initial call. Might be of help if you get to that point.
Good Luck out there.
Good Luck out there.
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Joined: Jun 2013
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I have a 2000 Lincoln Navigator 5.4 2wd and no salvage yards around here have what I need. I have 4 fuse boxes is what I read but I have no attempted to look for those yet. I read that they an be cleaned and I should seal my truck up with silicone. I am hoping a good cleaning will work and eventually replace them when I can.
I have 4 fuse boxes is what I read but I have no attempted to look for those yet. I read that they an be cleaned and I should seal my truck up with silicone. I am hoping a good cleaning will work and eventually replace them when I can.
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