This is my first time ever posting on any forum, anywhere. Usually i read as much as i possibly can on issues that i am having. That has never failed me, until now. I am stumped, and I need some help. Here is my issue:

I have a late 2004 Ford Excursion with the 6.0L. It won't start. In fact, it won't even crank.

It recently had this issue, and was related to the PATS module. The first time, i took it to a shop (we had just moved, and my tools were all in storage). They replaced the PATS module, and everything was good for a week. The PATS lost its program again, so i took it back to that shop. They diagnosed a bad main engine wiring harness. I agreed, because i saw all the damage to the wiring harness. I had it towed to the new house, and was able to replace the wiring harness just this past weekend.

Yesterday, i went to reprogram the keys using AE, but i couldn't connect to my truck. I have used AE many times with this connecter, cable and computer. I tried to also connect to the PATS directly in the AE selector (Instead of selecting "Enhanced Powertrain" i selected "Passive Anti Theft System" This connected successfully, but i am unable to train keys through that system.

I fear that the bad harness caused damage to the PCM, which is causing me to be unable to connect to my truck. When i connected to the PATS, i got a "Can Communication BUS fault" error.

Please help!

A little more about the truck -
2004 Ford Excursion 6.0L
Bullet Proof Diesel Air to Oil cooler conversion
Bullet Proof Diesel EGR cooler
Coolant bypass filter kit
separate gauges installed (exhaust temp, Fuel Pressure, Boost pressure, Oil Temp, Water Temp, Transmission Temp, Voltmeter)
Firestone rear airbags with onboard compressor and tank
Big 3 electrical upgrade

 

You might just had some hidden harness problems still. The more I think about
it the more I think this could be a factor.

What caused the damage in the first place?

I can pull up some diagrams later for you to look at.

Sean <BR>

6.0L Tech Folder

 

Oil and heat, plus some chaffing corroded the wires. When i pulled the harness apart, they all seemed to be melted together. I found many open spots on the insulation that were all touching.

Diagrams would be great. Anything that would help me trace these things would be helpful.

 

With a new harness have you rechecked all the connections to make sure the connections are locked and none of the pins are bent?

 

Did you check the cigarette plug fuse? It's the same circuit as the OBDII diagnostic connector.
If that's good then I'd disconnect the batteries with the headlight switch on for 20 minutes and then try again.

 

Connections are all good. I went over them a bunch of times after replacing the harness.

Cigarette plug fuse is also good. After checking that one, i put an ohm meter to all of the fuses in that box to make sure everything else was good, just in case something was wired funky and i didn't know it.

I will try disconnecting the batteries when I get home.

 

The PATS unit is tucked up in the lower center of the dash, right behind the OBD port ,between cig lighter OBD port should be some numbers on it to reference , maybe the new key fobs are not compatible with the unit or it's disconnected , you can Ohm at the Pats box.

 

Ok, i am back to working on this. I just double checked the batteries. One of them was dead, so they both went back and were replaced under warranty.

New batteries just went in, but the problem still persists.

I have another new symptom - No injector chatter when the key is turned to the "Run" position.

 

I wonder if the PATS transciever ring around the key switch itself is bad or bad connection.