Fuse #32 keeps blowing?

Tiny
BEETLEPUNK21
  • MEMBER
  • 2006 FORD EXPEDITION
  • 5.4L
  • V8
  • 4WD
  • AUTOMATIC
  • 270,000 MILES
This one is a doozy...

40,000on new engine.
Drove to work in the morning fine. Started vehicle in the hot afternoon and the overdrive light was blinking, vehicle went into limp mode and ran rough. No recent repairs were done or anything out of the ordinary.

Found out that fuse 32 kept blowing. I was told to unplug everything related to fuse 32 and see if the fuse would still blow. Then plug everything back in one by one and checking if fuse blew.

I haven’t started unplugging anything yet. Wanted to get your input.

Fuse 32 starts with the catalyst monitor sensors in the photo.
Friday, June 2nd, 2023 AT 3:18 PM

31 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

Wow, that fuse powers a million things. (Pic 1 below). Does it blow as soon as you install the new fuse or does the key need to be turned on? Also, since it was hot, chances are the AC was on. Do me a favor. Remove the compressor relay and see if the fuse still fails.

Let me know.

Joe

See pic below.
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Friday, June 2nd, 2023 AT 9:32 PM
Tiny
BEETLEPUNK21
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Thanks for getting back to me Joe. The vehicle needs to start for it to blow. It won’t blow with just key in the ON position. Also, where is the relay you’re referring to on the vehicle? I don’t have anything that looks like that diagram. It’s a 2006 expedition and there’s only one fuse box that’s below the glove box.
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Saturday, June 3rd, 2023 AT 4:41 AM
Tiny
JACOBANDNICKOLAS
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Hi,

We can skip the relay since it doesn't fail until the key is in the start position. Just to confirm, the fuse fails when the key is turned to the start position, correct?

If the fuse fails after you release the key, we need to start disconnecting one thing at a time that the fuse powers. If it fails as soon as it is in the start position, it will likely be related to the starter circuit.

As far as the auxiliary junction box, see pic below for the location. It's on the driver's side front.

Let me know. Sorry for more questions, but I'm trying to narrow things down.

Take care,

joe

See pic below.
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Saturday, June 3rd, 2023 AT 9:54 PM
Tiny
BEETLEPUNK21
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Joe,

I double checked and found that the fuse does blow when key is in the on position and not start/run position.

Also, I took pics of what I thought was the box you were referring to, but it did not look like the original picture you sent, so I wasn’t sure where the ac relay was. And there were no markings on the cover to indicate either.

As far as unplugging everything one by one, can you send me the diagrams of where everything is? I know where the oxygen sensors are but some of the other things I don’t know.

Thank you so much for your help!
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Sunday, June 4th, 2023 AT 1:20 PM
Tiny
BEETLEPUNK21
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Is the ac clutch relay the grey relay in the photo I sent?
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Sunday, June 4th, 2023 AT 1:36 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

It appears to be the relay. Isn't it interesting how they hide things? Ugh!

Do me a favor. Remove the relays in the CJB and see if it still fails. The relays are what actuate several things related to the fuse.

I have a question. My manual is showing two fuse boxes. One is the central junction box and the other is identified as passenger compartment fuse panel.

If you look at pic 2 below, that is the passenger compartment fuse box. If you have that, remove the relay that I circled first. Pic 3 is what I'm finding.

Let me know.

Joe

See pic below.
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Sunday, June 4th, 2023 AT 9:35 PM
Tiny
BEETLEPUNK21
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Hi Joe,

Yes, I have the passenger compartment fuse box as seen in pic 2.

I will work on it when I get home.

In case doing what you mentioned doesn’t work and I have to start unplugging everything one by one, can you send me the diagrams of where everything is? I know where the oxygen sensors are but the other things I don’t know.

That would really be a great help. Thank you, Joe, for helping me.
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Monday, June 5th, 2023 AT 11:31 AM
Tiny
BEETLEPUNK21
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I removed all relays in the CJB and fuse still failed. I removed relay #203 you circled from passenger fuse box and fuse did not blow. I believe r203 supplies power to f32 correct? So, it wouldn’t matter if I removed r203, right?
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Monday, June 5th, 2023 AT 1:50 PM
Tiny
BEETLEPUNK21
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I was going to plan on start unplugging everything connected to f32. Could you help with those diagrams of where everything is located?
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Monday, June 5th, 2023 AT 1:52 PM
Tiny
JACOBANDNICKOLAS
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Hi,

Actually, the fuse supplies power to the relay. Switch that relay with a different one having the same part number. See if that makes a difference. See pic 1 below.

Joe

See pic below.
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Monday, June 5th, 2023 AT 7:53 PM
Tiny
BEETLEPUNK21
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What you suggested didn’t help. Fuse still blows.
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Tuesday, June 6th, 2023 AT 1:03 PM
Tiny
CARADIODOC
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Hi guys. I've been vibrating in my seat waiting to learn the solution, but I see you've been wasting a lot of fuses. Please allow me to add my trick that will solve that. Use a light bulb in place of that fuse. All that will happen is when the short is present and the circuit is powered up, the bulb will be full, normal brightness. It will get hot so be careful where it's laid, and it will limit current to a safe value. My drawings show using a common 3157 brake light bulb. That will allow up to one amp to flow. Once the short is removed, the bulb will get dim or go out and the circuit will resume trying to work. If the bulb limits current too much, you can use a head lamp bulb instead. That will allow up to five or six amps to flow.

While this works great for fuses, I'm posting the procedure for bypassing a relay instead. I see a lot of mention of that. By bypassing the relay instead of the fuse, you usually can power the circuit without needing to turn on the ignition switch or do anything needed for that relay to turn on. I made these drawings over-simplified, but that's easier than trying to describe what to do. You do have to install a good fuse.

Joe can elaborate on where to find the items I listed, and which relay terminals to use if yours look different than those in the drawings. You can do this just as easily at the fuse socket too if you prefer. I hope this will help you guys figure this out.
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+1
Tuesday, June 6th, 2023 AT 2:41 PM
Tiny
BEETLEPUNK21
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Thank you for your help, I greatly appreciate it! This problem is frustrating and time consuming and I’d really like to get to the bottom of it!

Joe, what is the next step?
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Wednesday, June 7th, 2023 AT 9:04 AM
Tiny
BEETLEPUNK21
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Should I start unplugging everything related to fuse 32?
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Thursday, June 8th, 2023 AT 6:53 AM
Tiny
JACOBANDNICKOLAS
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Hi,

Yes, if you unplug the components associated with the fuse, it should prevent it from failing. If it does fail with the things disconnected, then we have a short to ground at some point causing the fuse to fail.

Once you disconnect things, reconnect one at a time to determine which component is causing things to fail.

Let us know,

Joe
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Thursday, June 8th, 2023 AT 7:58 PM
Tiny
BEETLEPUNK21
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Do you have diagrams of where everything is located?
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Friday, June 9th, 2023 AT 9:15 AM
Tiny
JACOBANDNICKOLAS
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Hi,

As far as locations, the schematics don't provide that information. Is there something specific you need help finding?

Let me know.

Joe
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Saturday, June 10th, 2023 AT 12:00 AM
Tiny
BEETLEPUNK21
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I’ve got all the 02 sensors unplugged, but I need help locating everything else.
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Sunday, June 11th, 2023 AT 5:18 AM
Tiny
JACOBANDNICKOLAS
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Hi,

I attached a pic of the PCM below. Before you disconnect the module, disconnect the battery negative cable. Also, disconnect the battery before reconnecting the module.

Let me know.

Joe
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Sunday, June 11th, 2023 AT 4:40 PM
Tiny
BEETLEPUNK21
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Wait, so I shouldn’t disconnect the items related to fuse 32? Should I disconnect the PCM instead? I’m a little confused.
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Monday, June 12th, 2023 AT 4:36 PM

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