Ignition switch? 2005 exp 4wheel drive

[TexEx]

Can anyone describe to me what occurs when an ignition switch has gone bad..I posted earlier about possible bad battery, so far I've replaced with new battery & over $100 for a fuel driver module thats located near the spare..has not worked...clicks coming from everywhere but mainly this loud hum coming from what seems to be the air intake, positive terminal is untouchable hot..perplexed

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[RichardH]

Couple of things. It seems like you have a lot of resistance somewhere. Sounds like your terminal/cable.

You mentioned earlier about buzzing from the passenger foot well area. I was also going to mention a smart junction box, but didn't want to jump to conclusions.

My SJB went slowly. Expy would not start. I also had buzzing there. I popped the hood and thought it was a terminal - felt a little loose but corroded - could not tighten. So I gave it a serious whack with the butt of a ratchet wrench and I was able to start the truck.

I have a spare 'iffy' SJB you are welcome to try out. Don't laugh, but I pulled all the fuses put them in a bag and taped it to the box. It's in the cargo area. I'm sure you are capable of reinstalling all the fuses. I keep them as back up.

Are you still in Spring? I'm in Houston. Send me a PM to chat or cell to call on Tuesday if you want to borrow it.

PS I went through some repairs several months ago involving similar issue - but my truck would start and stall repeatedly on the road. That involved both battery cables, starter cable dealer built harness/fusible link, Ford DPFE plus other crap. I tried an Amazon DPFE but dealer figured out it was faulty. Paid $$$ but truck is running great now. I also tried ignition module (not switch) and it probably had nothing to do with the issue.

 

[TexEx]

First of all thank you so much for taking time to explain your situations. Also thanks for offering up your spare sjb. This is my 3rd expy & I thought I had seen it all..on mother's day I just took a break from it & spent time with family/friends which was a good thing considering it almost got the best of me. Sunday night I decided to get back on it, I got word from another 5.4 owner about checking connections on starter & alt. He said make sure those were cleaned, brushed & even sandpapered if necessary. Well it turns out I inspected the ground connection to the starter & it was covered with the white powdery corrosion almost looked like snow. Cleaned it up like new & reconnected the battery & knew right away it was back! Turns out the previous battery had a leak & perhaps some of the acid ran down the cable (possibly).
I tested that same battery with a simple volt meter & it showed good, took it to the Walmart which to my surprise they have a load testing system evidently used frequently to honor their 3 yr warranty policy. New battery, no $ spent to replace..oh just a quick note I put a thick glob of red dielectric grease on the starter connection after cleaning it with MAF cleaner & small wire brush.
Thanks again!
Ted

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[RichardH]

Hey Ted,

No prob. That's what I believe we do here on the forum (and TX in general).

That sounds about right that you had corrosion on cable. Glad it is up and running. If anything changes the offer for using the SJB is always open.