Fuses And Circuit Breaker Problems of Ford Excursion

At night, in fog, in driveway, I turned on high beams, defrosters, wipers and lowered driver window. A major silver electrical circuit in the fuse breaker box overheated melted and popped. Ford's incompetent electrical engineer's design causes circuit board silver circuitry in fuse box to melt, while no circuit breakers melt/work. The circuit that melted also causes vehicle to lose use of indicators and gauges in the dash gauge panel, the alternator also fails to work and vehicle dies within a day, with no warning, while driving, due to totally dead battery. Ford has at least three different versions of fuse boxes for the 2003 Excursion XLT 5. 4l. Ford has no replacement fuse boxes to sell. Problem is so common on the internet, I luckily located the last used fuse box in the country, 1000 miles away from CA. Ford's only solution was a new fuse box for a newer f150 costing $750 and requiring hundreds of more dollars to modify it for an f250/f350/excursion. The melting fuse box happened twice in one year at $500 per failure. Technician had to put in an external bypass wire with its own external circuit breaker. No more meltdowns in 2. 5 years. Incompetent Ford electrical engineers.

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The contact owns a 2003 Ford Excursion. The contact stated that the gear shift lever sparked a fire and the wiring of the shifter began to melt. The vehicle was engulfed in smoke shortly after the failure. The contact immediately shut off the vehicle and disconnected the battery. The vehicle was taken to an independent mechanic. The technician stated that the wiring insulation of the lever had worn and caused the failure. As a result, the gear shift assembly would need to be replaced. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 145,000. In addition, the contact stated that the silver circuit box inside of the fuse box melted and caught on fire. When the failure occurred, all the gauges on the instrument panel and the alternator failed causing the vehicle to stall. The vehicle was towed to an independent mechanic, who stated that the fuse box would need to be replaced. The manufacturer was made aware of the failure and informed him that the fuse box was discontinued. The vehicle was repaired; however, the failure recurred shortly after. In order to remedy the failure, a modification had to be made to bypass the melting current by placing an external wire and circuit breaker. The vehicle was repaired. The failure mileage was 140,000.

1st failure: pulling out of my driveway and noticed that my security system "theft" light was blinking. This shouldn't be blinking while I am driving. All of a sudden I realized that I had no power when I pressed on the gas pedal. Then noticed that all gauges had failed. The engine continued to run but with no power to drive. Turned vehicle off and would not start again. Towed into covert Ford and their explanation was a blown fuse that controls the pcm (power control module). This affected the gas pedal because it is controlled by a chip instead of a cable. Covert Ford replaced fuse, checked out all wiring harnesses and could not find additional problems. Returned vehicle to me. 2nd failure: 2-1/2 weeks after 1st failure I was driving down the road and had turned off the "overdrive" at the end of the gear shifter. When I turned the "overdrive" back on I immediately heard a pop from the fuse box and noticed that my gauges had failed and the "theft" light was blinking. I continued to coast until I found a fairly safe area to pull off. Because I was going downhill at the time of failure I was able to get off the road. This vehicle was towed into covert Ford and is still with them. I am concerned that this is an intermittent electrical problem and that it will never be located. This is very dangerous because there is no prior warning signals. All of a sudden your engine is still running, but provides no power to the vehicle. The reason that I am reporting this is that there is a service bulletin addressing a similar problem. Service bulletin # 14044, seq # 136, date: 0004, NHTSA # sb613701 makes reference to a #19 blown fuse.

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