Ford F-150 (2004-2008) :: No Crank No Start After Removing Manifold / Head
Aug 29, 2015
2004 New Body F150 5.4L
Removed all cops, plugs, intake manifold and driver side head to repair bad valve. Removed Left side cat pipes as well. Had to disconnect most of upper engine harness and had to remove cpm and battery.
Repaired all mechanical issues and reconnected all electrical connectors and now when I turn the key to start the red security light on dash is still blinking steadily and I get no crank no start situation and it blows #34 PCM fuse which is injector/fuel fuse as soon as hit start.
Here are some things I have done trying to trouble shoot.
Battery shows 13.65 V
Unplugged FPDM back on rear frame rail and disconnected far left harness (looking from front) from PCM (should be engine harness), both the smaller plug that plugs into another harness and the main plug to the PCM.
Now when I turn on the key the security light goes out, the dash display says engine fail safe mode and the motor will turn over when I turn the key. This is still with the #34 fuse blown.
If I plug the engine harness back into the PCM, same no click no start.
If I leave engine harness unplugged from PCM and plug FPDM back in and turn key now it goes back to no crank no start and the security light blinks rapidly.
Only way I can get anything to turn over is far left harness disconnected, both plugs and the fdpm disconnected. Display says Engine Fail Safe Mode, and the security light goes out when I turn the key to start. I'm at a standstill as to what to do. The truck started fine prior to me taking it down for service.
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2008 F150 XLT 5.4L
1. Replaced fuse #9 for fuel pump.
2. Checked fuse #9 with check light, power to both sides is good
3. No check engine light
4. Battery is 1.5 years old. Just in case I charged for 1 hr.
5. Replaced fuel filter. Possible clog in fuel line.
6. Detached fuel line at fuel filter, turned key on and fuel came out of line. Seems like fuel pump is working.
7. Every time I can hear the fuel pump prim when I turn the key.
8. Relay#1 starter solenoid, I swapped with relay #2 and also replaced
9. FPDM replacement, I removed and it looked to be good.
10. Light checked all fuses, only fuse #5, fuse#35, and Fuse#36 did not have power. These fuses don't seem to have anything to do with starting or fuel to the engine.
11. Inertia switch check is good
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Went to leave this morning and my '05 with 135K would crank but not start. Pulled air cleaner and sprayed a little starting fluid and it fired some so I had a feeling it was fuel related. Reset the fuel cut-out with no luck. I then remember seeing the issues on the forum about the fuel pump driver module corrosion and failures. Bought a new one at the local dealer, installed it and it fired right up.
Pics below...from the side it didn't look to bad but was holed through on the bottom. I highly recommend replacing this if you live in the rust belt.
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So I used my 07 F150 4x4 Lariat (5.4 l) yesterday and it ran with no problems. Today, I went to start it to go to work and it would crank over strong and fast but not run. I filled up two days ago and it has been below freezing the last couple of days. What to check as I currently have my wifes explorer for work tonight.
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I was working on trailer lights and now no trailer lights and relays click but eng no crank. Batt has 12volts.
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06 5.4 screw. This truck sits in the garage all week long as I drive a work van daily. When I take the truck out on the weekends it starts up normally at the house and when I stop someplace for a few minutes it starts right back up but if it sits for an hour or more it will crank over for 10-15 seconds, it does always start back up. It always runs and drives fine, it is all factory as far as the motor, intake, exhaust, tuner etc. What to do with it.
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I have a 2006 Ford Expedition with 95,000 miles that has a crank but intermittent no start problem. When it does happen, it will eventually start after one to two tries. I don't have to wait to start it again and I don't have any problems while it is running. Two or three times in the past two months it will sputter out and die (even though I am pressing the gas pedal) right after starting. I'll crank it again and it starts just fine. I have no problems while driving at freeway speeds or around town.
I never had any check engine lights come on so I replaced the battery and the fuel filter. I finally got two codes and replaced the fuel pump driver module and the fuel rail pressure sensor. The codes went off after replacing these two parts. I can hear my fuel pump turn on every time I start the vehicle. I have even taken the entire fuse panel apart to check Relay 303 which is soldered into the circuit board. It is fine and so is every other fuse in the panel.
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I have a 2007 F-150 5.4l that does not crank when you turn the key to start. I have tried jumping the starter over and it does crank after that but it will not start. I am completely stumped by this and I'm not sure what the problem is?
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I have an 04 f150 and just changed the alternator yesterday, and 4 hours later it wouldn't start starter clicks but no crank.
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I finally decided to replace a leaky manifold as the low compression and leaking oil has gotten to be too much. Not sure but it looks like I'll have to remove the intake manni to get to it. A fortunate side effect is that the oil leaking from the manni seems to have lubricated most of what would be rust-welded bolts. I'd driven it like this since I bought it 3 yrs ago.
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Wifes F150 was turned off while she went shopping when she came out it would not start would crank but would not run. Got it home hooked up my scanner, had no codes, but the Service Engine Soon was illuminated on dash. Just wondering if this has anything to do with the PCM. Has a 4.6L engine, 2X4.
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i need to know if i can remove the light bulb for the flat tire light, it has gotten colder here in Phoenix, AZ and i dont need the damn bulb on. can i remove the bulb and call it good?.
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Looking for any pictures or directions on replacing the intake manifold on the 2004 F150, 5.4. Got all the parts with the pulgs, and ignition coils.
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I purchased my 2008 Explorer Ltd about 4 months ago with a 4.6L and 63k miles. I use it for towing a small travel trailer, so I don't put many miles on it. It's got about 66k on it now. According to OASIS, it has had all MFR maintenance performed up to the 60k mark.
In the past two months, it has developed a "sound" on startup. it goes away after about 75 seconds. To me it sounds like a typical exh manifold leak. That "3 cylinder, putt putt putt tractor" sound. There is no apparent affect on performance. It is definitely coming from the area of cyl #1. I have a recording here.
[URL]....
It is the "higher" of the sounds. The lower pulsing/whooshing is just regular engine noise. You can hear the regular engine noise as the camera pans to the back of the car.
What puzzles me is that the exh manifold sound goes away after 75 seconds or so. Holding the tailpipe shut for a bit builds up lots of pressure quickly. Do you think it IS, in fact, an exh manifold leak, and it seals up with thermal expansion as the engine worms up (75 seconds)? Is this a typical issue with the 4.6L
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I have a 03 5.4 F150 SCrew... The intake was leaking on the passenger side (water outlet tube meets plastic).
Putting in the Dorman replacement and noticed that the front cylinder drivers side (#5) had a decent amount of coolant in it.. None of the others did. I've drained the coolant already and was wondering should I just put this back together and see?
The water outlet crossing has a hole right next to this cylinder and I can't see any cracks and not sure if the gaskets were leaking under it.
Seems like if the head gasket was blown I would see it in more cylinders? It never smoked or run bad before I got this leak... Drove it maybe 10 miles with it leaking out onto Cyl#1. Ran fine, never missed.
I just don't want to put this back together if the head gasket is blown but I don't know what to do.
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I have a "VAN" Ford E350 and I need to check push rod on cylinder 1 and 5 left bank, how to do this?
Is ok if I remove the ARP head stup then check push rod and then re torque the head stud?
Full Story here : [URL] ....
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2005 Supercrew and my passenger side exhaust manifold was leaking. Son of a mother duck that was a joke to get removed. Front two studs broke off about 1/4" below the surface. Manifold is not cracked but putting a straight edge across it's out of plane at least a quarter inch.
Had planned on the dorman manifold but read some poor reviews about it cracking in less than a year and being warped out of the box. There is an ATP manifold with very few reviews but all good. Or just bite the bullet and do shorty headers? The driver's side looks a lot easier to access.
These trucks really weren't designed to be worked on after assembly were they? I had to invent new cuss words. Looks like Ford manifold is disco'd...
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Truck has 107 thousand miles; had to take it in for an manifold exhaust leak. Mechanic said bolts are so rusted they break.
1) was there ever a ALERT from ford about these bolt's?
2) Thought i read ford had stainless bolts for this problem...
I've had F150's only since the mid 70's and this 04 has cost me more in repairs than ANY previous F150..
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2004 SCrew, FX4, 5.4 ... I had the dreaded exhaust manifold leak on the passenger side. After reading the horror stories of this repair and living in the rust belt I decided against fixing it myself. I took it to a local repair shop to have done. Initially the mechanic could see that the front 2 studs were snapped off (before even trying to remove them).
After a full day of fighting the studs (engine loose & lifted up) everything is out but the front 2 studs. the top one has about 1/2" exposed, but it is frozen in place (penetrate on it overnight). The biggest problem is the bottom stud. it is broken off about 1/8" below the surface of the head. The guy doesnt have a small enough right angle drill to get between the frame & head to attempt to drill it out. I will gladly go buy a drill for him to do this, as it will likely save me money if it will work to drill out the stud.
Need to get the 2 studs out, particularly the bottom one, or what right angle drill may fit in there?
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I have a 2006 F150 screw 4.6 auto 116k miles that has evidence of a small coolant leak where the intake manifold joins the head. This is on the drivers side directly under the thermostat housing. The t-stat housing is dry and the hoses all appear dry. It's just wet right at the gasket where the manifold joins the head. Reservoir is still normal so it's not leaking too much just yet.
I searched this site and youtube but didn't find any other posts. Lots of problems with older trucks with composite manifolds but nothing for this one. It looks like a part of the bottom of the manifold is plastic but the entire top and where it is leaking is all aluminum.
It seems odd that this would start in the winter time just driving back and forth to work (no load). And, yes the antifreeze is good. Just wondering if this is a known issue with this truck. Is it just a matter of replacing the gaskets or is there some other flaw I should be concerned about?
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I have a leak between the metal and the plastic of my water crossover.
Do I need to remove the manifold to replace the gaskets for the crossover and if so looking for a good thread showing how.
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