Help!!!!

[jbaroni]

My wife is on her 2nd expedition. My wife will not drive anything else.
We live in a area affected by hurricane Isaac. Since the storm, if she drives the beast and shuts it off, and comes back to start it after about 20-40 mins, it will not crank. All lights and other electricals work but it just won't crank. I am a ASE certified Tech but not with Fords. I have tested the starter, alternator, battery and solnoid. All are good. If I put the key in the run position, I can jump out the solnoid and make it start and run without a problem. I think something got wet during the storm although we did not get flood waters, just heavy wind and rain. After the beast cools off for about 1 hour, it will start fine. I've tried both keys so its not a Pats problem. At least I don't think so.
Anyone got any suggestions? I'm stumped. My wife not carries around a screwdriver to jump out the soliniod when it won't crank. I need some help, please. The local Ford dealers are full of flooded vehicles and can't get to mine for several weeks.

 

[Alienxtx]

Have you tried disconnecting the battery for a while and letting the comp reset yet? Might be as simple as that.

 

[toms89]

It could be the park/neutral safety switch, ignition switch or gem module/ fuse block.

If the gem module or fuse block gets wet it can cause all sorts of electrical issues but since your only symptom is a no start condition I would think the problem is elsewhere!?

When it occurs play with the tranny gear selector moving it in and out of park or neutral and see if it makes a difference.

If pats is activated it can still crank but will not allow it to start. I know this through experience..

 

[jbaroni]

I have not tried to disconnect the battery for a reset. How long do I need to leave it disconnected? I will try this.
I did try moving the gear selector and did try to start it in neutral. No difference.
Are there some places that water can ingress to modules, fuse boxes during heavy blowing rain? Does anyone have experience with this?

 

[Exia]

I had a similar problem but with a Camaro, I could drive it but, park it come back 20 minutes later nothing, would have to let it cool off before it would start, I did the same as you tested everything, but I found the issue was indeed the starter, due to the heat of the engine, and how close the starter was to the manifold it was basicly killing the starter. This "may" be the issue I would take it and get a $25 rebuild job

 

[toms89]

I have not tried to disconnect the battery for a reset. How long do I need to leave it disconnected? I will try this.
I did try moving the gear selector and did try to start it in neutral. No difference.
Are there some places that water can ingress to modules, fuse boxes during heavy blowing rain? Does anyone have experience with this?

Disconnect battery. Turn lights on and crank ignition....this would remove any capacitive charge in the ecu. Turn ign and light off reconnect battery.

The wiring harness behind the dash leads downhill right to the gem/fuseblock. If you study it you will understand why if any water gets behind the dash it follows the cable right to the gem/fuse block. I had some strange electrical issues and it turned out I had water in it. As I was removing it water poured out !?!. Was able to remove and dry out and have not had a problem since. I can see a driving rain getting past the drivers door seal and getting in there. I originally thought my windshield leaked as it was just replaced but it may have made its way past the drivers door seals?!

Heres my original thread on it....http://www.expeditionforum.com/f16/interesting-issue-14336/

 

[Jay87LX]

I am leaning towards what Tom is posting, Expys have leaking windshield issues

 

[Bowesmobile]

I had the same issue without the hurricane. Its your cables that run to the starter. You can buy replacements from Ford. But I decided to buy individual cables from Advance Auto parts. If memory serves they were a 42" positive with hoop connector on both ends. Then a 24" from the battery to the firewall solenoid with a battery connector on one end and a hoop on the other. The negative is a 42" with a battery connector on one end and a hoop on the other. I reused the smaller cable for the trigger wire on the starters solenoid. What happens is the cables run by the exhaust manifold on their way to the starter. The heat breaks them down to where only a few strands are left connected in the cable. It carries enough voltage but can't transfer the amperage the starter needs. Resulting in a no start. Try this and let me know.

 

[Thermo]

jbaroni, what year truck are we looking at here? If you are looking at a 97-02, I will place money that your windshield is leaking and is raising hell with the GEM module.

 

[toms89]

@ bowesmobile

That makes perfect sense but to me it sounds as if the op jumps the solenoid with a screwdriver. If this is the case and the starter cables are bad it still should not start. That makes it sound like a bad solenoid but he said he tested it so that leaves the circuit from ignition switch to solenoid. Still possible the solenoid could be faulty and just temperamental.

Testing for voltage on the ignition wire at the solenoid during no start would confirm where the problem lays. As someone has ignition key in crank position of course...

Though windshield leak is a common issue with the early expys the windshield does not necessarily have to leak to get water behind the dash. Leaky door seals could also be an issue. Have seen video posted where gem module issue was traced to leaky door seal. Add driving torrential rains to the equation and........