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I had only one key when I purchased my 2006 Navigator earlier this year. I went to the local Ford dealer to get a replacement key and have them cut it. I took it home then used the FORScan program on the laptop to program both of them.
Then I found out when I wiped out the stored key information it also dumped the aftermarket remote start module from the PATS memory.....Another 2 minutes, that was resolved too.
If you already have the capability to use FORScan under Windows, it's easy and way cheaper than either buying a clone ($60-70) key or going to a dealer.
Buy a replacement blank off ebay or Amazon that is for your vehcile. Get it cut - Home Depot, for example, will cut it, usually for free. Make sure it's a mechanical fit for all the lock cylinders before proceeding.
Connect to your car's system in FORSCAN, follow the easy on-screen directions to either simply add the new key or to wipe all keys and add all back in. It really is that simple.
Remember to TEST the key by programming it first and making sure it will accept the programming and start the vehicle, BEFORE erasing the stored keys from memory! Some of the aftermarket key blanks you buy may not work, and when you program keys after erasing you MUST have minimum 2 working and programmable keys or else the programming process will FAIL and leave you with a vehicle you can't start.
... and to add a further layer of complexity, it's necessary to first verify that there are open slots in memory for an additional key before any more can be added. If there are none, then it's not possible to program in any new ones, as well as reprogramming any existing keys, until... you guessed it... you erase them all.
I bought my 02 Navigator with only one key. With mine I was unable to program a new key without first wiping out all the keys. It was somewhat unnerving to wipe them all out, because if they didn't program I wouldn't be able to start the car and probably have to get it towed to a dealer. Fortunately after FORscan erased all the previous keys, the program mode worked and I now have three working keys.
... and to add a further layer of complexity, it's necessary to first verify that there are open slots in memory for an additional key before any more can be added. If there are none, then it's not possible to program in any new ones, as well as reprogramming any existing keys, until... you guessed it... you erase them all.
Fun, ain't it?
Yep, that's right. But I presume it's a fairly rare situation to have all slots used. FORScan should be able to tell you how many keys are programmed as well if I remember correct.
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