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Well, I went to my local Ford dealer and about got robbed... After $200... (for looking at my truck) they couldn't figure it out and wanted to "trouble shoot it" for a couple more hours...
Too rich for my blood, I guess I will just have to live with this problem
I have been having the same problems with my 2003 X Gasser. The instrument gauge cluster fuse blows non-stop and is now getting more frequent. It used to blow about once a week, now it is everytime I turn the truck off. In addition to that fuse the driver power seat and adjustable mirror fuse is always blown. I will try and bring it in next week to see if this problem falls under the warranty I purchased with the truck. If any luck I will post the results sometime next week.
A couple of months ago I put a resetable 10 A circuit breaker in the place of the fuse. This continued to trip - sometimes once a week, sometimes 2 or 3 times per day. I just found out that it occured while changing gears with the shift lever. Also, today, everything has quit completely - no gauges, accelerator, etc and the breaker is not tripped. I guess the problem has finally stopped being intermittent. Now maybe I (or Ford) can find the problem. I can't drive it until it is fixed.
I just found out that it occurred while changing gears with the shift lever.
I had a problem similar to this in a E250 except my headlights went out. It happened randomly when I turned it off, it would smoke the fusible link. Dealership was stumped and couldn't trust that I wouldn't get stranded in the dark. One day, I notice that at the same moment (this one time) that I put on my parking brake, it smoked. I pulled part of the dash out and found that the P-brake assembly was chaffing a main wire. Taped it up and secured it out of the way and reliability was restored! It sounds like you may want to look for something rubbing, in my case it rubbed alot without causing a problem, and then when things aligned right. Boom, problem surfaced, it was aggravating. I hope this may shed some light or give you something else to look for.
Sorry for the delay in the response, the problem with my fuses was inside my driver side door. The arm that holds the door half way open was searing the cluster of wires that leads into the door. Took me about ten minutes to get into it resolder the wires and no more problems. Hope this can be of help to anyone.
kelfolso, pull the shroud off of the steering column and check the wiring to your O /D
switch inside the gear selector lever. These are known for chafing and shorting to
ground on the column. One splined pin is all that holds the gear selector lever in.
Fixed a bunch of these.
I think I have determined that the problem was the OD switch wiring. I disconnected it this weeked and drove around all weekend with no problems. I spent a lot of time shifting the gear shift lever (which previously caused the fuse to blow). No problems, even though I do not see a chafed wire. I did have to by-pass the circuit in the fuse box because the continued tripping of this circuit breaker must have damaged something in the fuse panel. Ford wanted $266.00 for a new one, so I just bypassed it with and external fuse. If I have no more problems in the next week, I'll pull the shifter off and look again for a chafed wire. If I cannot find it, I'll replace the whole assembly. It's only $40.
I had the same problem,wire was chaffing on the shifter,shorting out and causing fuse to blow.Thanks to you guys it saved me probably lots of $.It just took a little searching on the forum,and it turned out to be a 15 min. fix.
This site is my #1 Ford resource without a doubt. It's great to hear that you fixed and saved money. Maybe even more when you consider that it is not always fixed the first time when you pay someone to do it. You probably avoided a big hassle which will actually add to your life. Acoonamatada!
Well I paid the price of the dealer-------$200 dollars later and it was the shifter that was shorting out. Small dealership but they had a shifter----FIRETECH WAS CORRECT!!!!!!!!!!!! Must be a very common problem.
Had the same issue with my 1999 F250 SD. Chafed wire in the steering column. Fount the problem, re twisted the wires and double wrapped with some good heat shrink tubing and problem has been fine for 4 years now. Looks to be a design flawon all the X and SD models.