03 Expedition PCM Relay melted/bad

[scoot0073]

For the last 4 days I been dealing with battery drain . Rig sits for 3 hours and the battery will be dead reading 3.4v with my digital volt meter.
I haven't added or did anything electrical wise that could be the issue. So I today I tried to figure out what is killing my battery so I went straight to the Fuse panel passenger side kicker panel.
And pulled the PCM Relay and noticed one of the prongs was melted and I could here the relay rattle when shacking it.
So it's a $18 Dealer item only. Bc I done had to replace the Starter Relay twice in 1 year and it is next to the PCM Relay. So lucky for me my cousin had a 04 Explore that is a parts car and he let me take all 3 out of it.
So I put the melted relay back in and pushed it upward and Rig would run/start but if I pushed it down it would die.
So put the used replacement relay in and Rig starts fine I pushed it up n down and there is no movement like the old relay.
Rig has been sitting for 4 hours and it's still reading 12.4v so the bad/melted relay was causing my battery to drain and when it was charged the Rig wouldn't start.

Which is a BIG relief that I found the problem.
But now I'm thinking I might eventually have to replace the whole fuse panel as I have read many stories on here of them going bad..

But anyways thought I would share my headache in case it could help someone else.

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[Hamfisted]

Yes. The melted PCM relay is the first sign of a failing fuel pump relay on the fusebox. Always keep a spare relay in your glove box, at least till you replace the fusebox. There's a method of jumping the relay in an emergency, you'll find it discussed on a few of the forums. You can decide if you really want yourself or a spouse to be doing that on the side of the road one night. The replacement fusebox is supposedly upgraded and there haven't be any reports of replacement failures. So my recommendation would be to bight the bullet and replace the box at your convenience, rather than in an emergency and have to pay shop prices. It's a plug and play exchange.


-Mike



https://www.ebay.com/itm/Genuine-OE...224556&hash=item4b17c28020:g:70YAAOSw-K9ZHeNB

 

[scoot0073]

Thanks for your input. Yeah I've read on here about doing the jumper trick during my search on here about my issue.
Yes I got 2 extra relays I put in the glove box.
Good Lord...$300 something for that part now I see what u mean by bite the bullet..hahahaha
Well I'll get the fuse panel for sure then just gotta get the money up and hope these extra relays hold up till then..
This sucks but then again it could always be worse..
This is the most expensive thing that I've had to do in the 5 year's of owning it.

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[stamp11127]

That is a standard mini relay. Depending on the amps it can handle you should be able to find them on ebay.

Here is a link to 6 of them rated for 20A:

https://www.ebay.com/itm/6pcs-Car-A...265353&hash=item4b18ddb5f4:g:IPgAAOSwZ4dZMNLG

I'd try fixing your current box if you have the tools and know how and keep the $300.

The melted plastic on the relay and fuse box indicates the connection to the relay was poor and produced heat and resistance as a result.

 

[scoot0073]

Made a trip to my cousin's house and got a few of them relays to keep n the Rig till I get the money up for the Fuse Box.
And I grabbed a few of others

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[1955moose]

If you don't want to mess with repairing your old panel, I saw 4 fuse panels for 2003-06 Expeditions on EBay. They averaged around $15000 Keep in mind though that their very specific, so matching part numbers is critical. Or the cheaper route is pull one yourself from a pick and pull, or equivalent in your area. Again be sure the #s match, theirs at least 2 different models for 03 alone. Anyway let us know when all is fixed, and what you did.

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[scoot0073]

Thx Moose I just need a couple weeks and i should definitely able to order a New one . And there is no 03 to 06 Expedition in the junkyards here , so a used one is not a option.
It is just bad timing bc I am in the middle of getting everything together for my bump. But not a big deal..lol
I just got alot of extra relays just in case they go out every other day..lol..

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