Need some eyes on this one. We've owned the SUV since new. 150k and babied since new. Over the last year strange un-recreatable random things have been happening.

Here is the rundown:
a). Unlock the doors with FOB and the truck kills itself ! (No power at all! DEAD as a doornail! - must use key to open door- cannot start without pulling the battery terminals/ total system re-boot - wife loves doing this in the rain and snow....) Was happening once a month, Now happening 4-5 times a week.
b). CD changed will randomly shuffle CD's when there are no cd's in the head unit.
c). bring windows up and truck puts them down with hands off the switch- over and over again...
d). Low beam headlights (Both) stop working at the same time- high beams work fine (same bulb H13/9008) - Switch set to automatic- will not turn on manually either/ checked fuses and they are fine. must pull the battery and fuses to get lights to come back on.

Had the truck at two Ford dealers and they cannot recreate any of the issues because they are totally random. No stored codes. after days of trouble shooting they give up and send it home - usually kills itself (Electrically) the next day.

Local mechanic added a new body ground and changed 3 relays - didn't help. We checked for voltage drop and replaced the battery for the hell of it- didn't help.

I'm a computer engineer by trade. This situation really pisses me off! We are very logical by nature. In my world: The definition of insanity is doing the same thing over and over again and expecting a different result!

Any input would be appreciated-

unrelated:
Two years ago had the "Limp mode" issue.. Three weeks at the dealer - couldn't figure it out and a new $1,500 wiring harness.... has been fine since

 

It sounds like a power delivery issue to me. I'd start by inspecting all of the battery cables, or possible just changing them in case one is internally broken. In the meantime you can install a battery switch to use when resetting the system. It's not a solution but it will keep the wife a bit happier.

 

Thanks for taking a look. Yes-. I put the switch in for her before the holiday and it's better than her carrying a 8mm wrench in her pocketbook. Since then, when the electrical system reboots the headlights flash a couple of times. Every once in awhile after this reset process the low beams stay off. (Highs work fine... same bulb) To get the headlights to work again I pull the two fuses and magically I have low beams again. I'm stumped.....

 

Wow, what a mess. Could water is getting into the electrical systems?
Richard

 

I was thinking that as well. but it doesn't happen any more or less when it rains- It just does it randomly.... I did notice that over the last two summers I'm getting the AC condensation buildup around the passenger foot well that others have noticed. Also noticed the rocker panel on that side has rusted through from the inside.

 

There is a fuse box and some other electrical devices located in a fuse panel in the passenger foot well. The interior side panel must be removed to see in there.
If the carpet has been getting wet there you may find the 'ghost' in there.
Good luck
Richard