Engine will not shut off

JustSean · Apr 6, 2022

I have an 03 Expedition 5.4 Eddie Bauer. All of a sudden my engine and all the electrical will not shut off when I turn the key to off. I can even remove the key and nothing shuts off. I replaced the switch itself but that did not resolve the issue. I have to disconnect the battery and alternator to get it to turn off. No matter how much I search I cannot find anyone else online who has posted about a similar issue. Service places are over a week behind and I need to get this fixed as soon as possible since it is my only way to work. Anyone have any ideas?

Alwaysthinkin · Apr 7, 2022

Don't have the answer but here's a BUMP....

Welcome to the Forum!

JustSean · Apr 7, 2022

I think I found the issue. It appears to have been the power relay. Relay #203 on the fuse block.

Hamfisted · Apr 7, 2022

Is it still the original fusebox ? Usually that PCM relay burns, then the fuel pump micro relay ( it's soldered onto the circuit board...) fries, and your fuel pump dies. You can replace that relay, but inspect the fusebox contacts for burn or melted plastic as well. Keep a couple extra relays in the glovebox.

Ford PCM Relays ( SMP RY612 ) on Amazon

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Vincent Vega · Apr 8, 2022

@Hamfisted Other than carry a spare $400 fuse panel, is there anything I can do proactively so that my fuel pump relay doesn't fry and leave me somewhere?

Hamfisted · Apr 8, 2022

Vincent Vega said:
@Hamfisted Other than carry a spare $400 fuse panel, is there anything I can do proactively so that my fuel pump relay doesn't fry and leave me somewhere?

If it's the original one, replace it and keep the original for a spare. How many miles on your Expy ? The original will last 100k but after that, every day is a gift .... the replacement ones started using heavier duty Panasonic relays and had no problems.

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Vincent Vega · Apr 8, 2022

Hamfisted said:
If it's the original one, replace it and keep the original for a spare. How many miles on your Expy ? The original will last 100k but after that, every day is a gift .... the replacement ones started using heavier duty Panasonic relays and had no problems.

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I have 150k on it, so will put the fuse panel on the list along with ball joints, rear blend door motors... It never ends. Thanks

Hamfisted · Apr 8, 2022

Vincent Vega said:
I have 150k on it, so will put the fuse panel on the list along with ball joints, rear blend door motors... It never ends. Thanks

You should get a little warning with that PCM relay burning up first ( carry a spare in the glovebox...). But as with everything in life, there's no guarantees. The '03s were really plagued by this, but the late production '04s don't seem to have it as bad. Maybe the revised fuseboxes were out by then. I can't remember.

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Old Guy · Apr 11, 2022

Hamfisted said:
If it's the original one, replace it and keep the original for a spare. How many miles on your Expy ? The original will last 100k but after that, every day is a gift .... the replacement ones started using heavier duty Panasonic relays and had no problems.

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The idea of replacing with a new one and keeping the old one, which was working as a spare is exactly what I do. I have been a boat owner for 50+ years and use it a lot. On boat # 14 now and have been towed in 2 times... in 50+ years.

bigdogchrisl · Apr 11, 2022

Old Guy said:
The idea of replacing with a new one and keeping the old one, which was working as a spare is exactly what I do. I have been a boat owner for 50+ years and use it a lot. On boat # 14 now and have been towed in 2 times... in 50+ years.

14 boats and only towed 2 of them?

Kidding obviously. That approach is solid, well, except for wives.

Engine will not shut off

JustSean

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