jbanks
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I have a 1st Gen but I saw this and thought it might be helpful to someone here in the future using the search function:
Intermittent stalling and would not restart : Justrolledintotheshop
Here's the link to the pictures:
Intermittent stalling and would not restart - Imgur
From the link and the guy that diagnosed and repaired:
Well just to clarify some things i am actually the the guy that diagnosed and repaired the vehicle. The family is on a very tight budget and could not afford to replace the fuse block that had failed. We called some local salvage yards and no luck. My boss asks if there is any way to repair the fuse block so i said sure just will take some time. Ive repaired many circuit boards with no problems. So I pulled the fuse block apart and found the reason why it failed. If you look at the terminals there are three that are the same. Two of them are the control terminals for the relay (low current) and and easily handle the load. The other terminal that failed is unable to handle the current so it gets hot and fails. The larger terminal not on the board that i attached the grey wire too is undamaged and can easily handle the current load. The relay sends power to multiple fuses attached the board. So i start by resoldered burnt terminal to the board after repairing terminal i then overlaid a wire on the board to ensure no future problems. Then I soldered the wires to all of the terminals for the relay and used heavy heat shrink to minimize movement at solder joints. Next i drilled holes in fuse block cover where the relay originally retained to hold the wires in place and it was a very good fit no movement at all because yes a solder joint is fragile if flexed thats why the wires are long enough to allow me to only bend unsoldered portions of the wires. The fuse block is located inside of the car in the passenger side footwell area so there are no extreme vibrations that are going to break the solder joints and the relay is secured the the fuse block so it can not move all. The factory covers all fit and work perfectly. So in short ford did not properly engineer the panel all of the other terminals on the panel for the high current portion of the relays were a large enough terminal to handle the load but that one. So it should now be a happy fuse block for years to come.
Intermittent stalling and would not restart : Justrolledintotheshop
Here's the link to the pictures:
Intermittent stalling and would not restart - Imgur
From the link and the guy that diagnosed and repaired:
Well just to clarify some things i am actually the the guy that diagnosed and repaired the vehicle. The family is on a very tight budget and could not afford to replace the fuse block that had failed. We called some local salvage yards and no luck. My boss asks if there is any way to repair the fuse block so i said sure just will take some time. Ive repaired many circuit boards with no problems. So I pulled the fuse block apart and found the reason why it failed. If you look at the terminals there are three that are the same. Two of them are the control terminals for the relay (low current) and and easily handle the load. The other terminal that failed is unable to handle the current so it gets hot and fails. The larger terminal not on the board that i attached the grey wire too is undamaged and can easily handle the current load. The relay sends power to multiple fuses attached the board. So i start by resoldered burnt terminal to the board after repairing terminal i then overlaid a wire on the board to ensure no future problems. Then I soldered the wires to all of the terminals for the relay and used heavy heat shrink to minimize movement at solder joints. Next i drilled holes in fuse block cover where the relay originally retained to hold the wires in place and it was a very good fit no movement at all because yes a solder joint is fragile if flexed thats why the wires are long enough to allow me to only bend unsoldered portions of the wires. The fuse block is located inside of the car in the passenger side footwell area so there are no extreme vibrations that are going to break the solder joints and the relay is secured the the fuse block so it can not move all. The factory covers all fit and work perfectly. So in short ford did not properly engineer the panel all of the other terminals on the panel for the high current portion of the relays were a large enough terminal to handle the load but that one. So it should now be a happy fuse block for years to come.
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