I think you are correct. It is a voltage issue. You don't know what's causing it, though. It could be a ground, corrosion, a hardware fault, a bad battery cell, or who knows. If the dealer doesn't want to deal with it, at least you have data when you escalate it to corporate.

 

UPDATE:

Drove through some rain last evening and it rained over night. This afternoon once again it didn't start first start of the day and the same fault codes came.

Forscan logged 2 additional DTC Codes.

I called Ford Customer Service and reopened the case. Told them I need it either fixed or replaced.

Called dealership and Service Writer will talk to the diesel tech in the morning and call me back with a time to drop it off.

Right now I'm getting all paperwork ready to go the BBB autoline route. Florida uses them as first line for Lemon Law. I special ordered the truck and I can't find a truck within 200 miles equipped like mine.


Recorded Codes

===IPC DTC U0104:00-08===
Code: U0104 - Lost Communication With Cruise Control Module
Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
Module: Instrument Panel Control Module
===END IPC DTC===

===ABS DTC U0104:00-08===
Code: U0104 - Lost Communication With Cruise Control Module
Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC
Module: Antilock braking system
===END ABS DTC===

 

UPDATE AGAIN:

Truck was dropped of last Wednesday for 3rd visit for same problem. Since dropping it off there has been no communication at all from dealership for 6 days so late last night I sent an email to the Service Director.

This morning the service writer called at the request if the Service Director. He said they are working with Field Engineering and they found 10amp vs 20 amp fuse in start circuit and found corrosion on the start/run relay. They finally are checking all connectors for corrosion. They will replace the relay today and if Engineering agrees they will return the truck to service tomorrow.

In the mean time I searched the country for a 2019 Lariat equipped like mine in case need to follow up with Lemon Law and I can’t find anything. I special ordered mine to maximize payload for towing a 14,000 lb 5th wheel and still have great options. I absolutely don’t want Sun Roof or 20” wheels yet I must have power running boards (short wife) Adaptive Cruise, 5th wheel prep, upfitter switches, LED Headlamps, Tow technology and Ultimate package.

Hopefully they get it fixed this time which is my preference. . If not I’ll go Lemon Law route and request another ordered truck.

 

Hopefully FINAL UPDATE:

Dealer could not reproduce the No-Start issue. They had a Field engineer come on site and decided to replace the big main harness. Prior to replacing the harness they found that they could reproduce the exact same DCT codes I captured by removing the Start/Run Relay. The pulled the relay, disassembled it and found that the internal contacts were corroded. They replaced that relay and the fuse block in that area and returned the Truck to me. Hopefully it is fixed.

The Service Director showed me all the pictures of the corrosion and harness they almost installed.

 

It's been 3 weeks now since the relay was replaced and no more issues. The Start/Run relay seems to have fixed the faults.

I once again LOVE this truck. Today I hooked it up to the 5th Wheel for a Thanksgiving camping trip tomorrow. When I picked up the 5th wheel from storage facility it had a bad battery. I quick trip to Costco and $89 later new Interstate 27DC installed and we are ready to go camping. Leaving in the morning.

 

Great news. I was lurking around your thread and curious to see if they finally found the problem. 👍

 

Update:

I just left dealership for 3 recalls. The dealer told me he had another truck with the same exact issues as mine and this time they knew what to do to fix it.

BTW, MY Truck is fixed for sure, no start problems in 4 months.

 

i spoke too soon. At 8 month mark the gremlin came back. Last 3 days the first time truck was attempted to start it wouldn’t and the faults reappeared.

I took it to the dealership today and they ordered a wiring harness. They said they had another truck 3 weeks ago with exact same issue and harness. Fixed it. Said it’s a big job but the tech now has experience replacing the harness.

BUT they warned me it will take 2-3 weeks to arrive from supplier back ordered due to Covid shutdown.

 

Thank you for your thorough follow through on this problem. This is what is the best use of this forum; Identify real problems and track them through to a resolution.

 

Todays update: I dropped the truck off at the dealership for first thing Monday morning.appt to install the new harness. I was told 2 days but now after 3 full days they’re still working on it. The service writer said “ I hope this fixes it” so I’m not confident.

So today I filed Lemon Law paperwork with FL State Attorney, sent the “Notice of Defect” to Ford via registered letter, called and filed BBB Autoline request for arbitration paperwork and opened a BuyBack request with Ford Customer service.

Ford said they should have a decision within 5 days. Has anyone been through this and if so what can I expect?

 

UPDATE:

Picked up the truck after being in shop for 3 solid Days to replace the "harness"
Here is detail from service invoice: HOPEFULLY EVERYTHING WAS PUT BACK CORRECTLY!
Service writer said thisis the 3rd truck that they replaced the harness on due to intermittent complaints and none have been back..


-----------------
Intermittent bad connection in BJB. Verified complaint.

KOEO, no DTCs. Concern comes and goes banging on the BJB, TSB 12-2294 and SSM 47899 has already been performed.

Contacted Hotline #117339541.

Pinpoint. Check ea batteries and cables, passed.

PPT Bl no. B2 no. B3 yes. B4 no. B5 yes. B6 no. B7 yes. B22 no.
PPT B did not provide a cause.

Drained coolant.
R and R battery tray and coolant bottle.
R and R wheel wells.
R and R BCM.
R and R front grille, equipped with camera.
R and R headlamps.
R and R wiper cowl panel.
R and R CAe tubes and cooler.
Disconnected BJB harness.
Removed old harness from vehicle.
Compared old harness to new.
Installed new harness systems.
Test drove and retest.

 

So what’s your plan now? Are you going to give the truck a knot her chance or are you still wanting to lemon law it? I’ve followed your wild ride from the beginning. Hope it all works out which ever way you want to go. 👍

 

Teddy,

Ford is supposed to get back with me in 5 days. I’ll see what they offer. When negotiating I never open with the first offer so let’s see what they offer. I prefer to do this without an attorney but if need be I can go that route. The LL attorney approved taking this on but I haven’t signed the retainer agreement.

I don’t trust the truck at this time. My preference would be a replacement truck equipped just like mine. I searched the country and I can’t find one like it so it would need to be a special order. Let’s see what Ford offers either through Lemon Law, BBB arbitration or their Direct buyback program.

BBB and Ford should get back to me next week.

I’ve been through this 2 times before, once with a 1997 Oldsmobile Bravada that would backfire and stall out in intersections and once with a 2000 Ford Expedition that intermittently spewed horrible sulphur odor, so I know the ropes. Both times vehicles were replaced by the manufacture.

The last repair attempt on my truck lasted 6 months and I really thought it was fixed. But now I’m not confident that this attempt is a permanent fix.

My background is in electronic and mechanical troubleshooting. I worked Avionics for 6 years in both the field and as a manufacturing tech rep. Then I spent many years as third level field engineer for a high tech Fortune 550 company covering most of the State. I was the one who got involved and had to resolve these types of difficult problems so I have sympathy for the techs.

So let’s see what Ford will offer.

 

Update:

2 weeks ago Ford agreed to a buyback. I don’t yet have numbers in writing but they said they will follow Florida Lemon Law guidelines which is refund all costs, interest paid fees etc minus a usage fee. Usage fee is calculated (Miles driven/ 120000) X MSRP. They also will offer a private cash offer that can be used if I buy another Ford. Or I can just take a check for that amount. Usage fee in my case would be $5,900

Other option is replacement which is calculated MSRP TO MSRP difference plus same usage fee. I can choose any model I want.

They are OK with dealer special ordering if I can’t find equivalent or something else that I like.

Now, due to pandemic they are short staffed and the offer calculation will take another 10 days to finalize and go through quality approval. Right now 2020s can be ordered but if they stall too long it will be 2021 order time.