2002 Ford Explorer Malfunction - Electrical & Lighting Systems

Question: Power drivers seat blows fuses randomly. Been to dealer 4 times - they took whole motor/harness/switch assy out - never find a problem. Might work fine for up to 2 weeks. It does NOT fail while in use - this is the weird part - you can replace the fuse and two weeks later it might be blown EVEN IF YOU NEVER USED THE POWER SEAT IN THE MEANTIME! Put ammeter in series - motor is drawing 3A forward/back 6A up/down - seems normal- fuse is 30A.

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Technican: Thank you. I can access the Mitchell 1 Auto Repair Data Base on Sunday afternoon for free at my local public library. I'll be looking for any Technical Service Bulletins (TSBs) that apply and get a wiring diagram for the power seat system. There must be a wire rubbing somewhere (or pinched) that causes the short to happen without being activated by a control switch. I'll find out what color wire is between the fuse and the control switches for the seats. That will be the wire to trace for a short. Sometimes you get lucky just wiggling the harnesses and "induce" the short. Question is what to wiggle and where?

Owner: There are no other components on the circuit (verified my Ford dealer). Fuse is labelled "power seat" in the owners manual.

Technican: Hello, Have you an owners manual that tells what else is protected by this fuse? When I get to the data base for a schematic to study I'll be better prepared to help you. I'm used to power seats being on a circuit breaker. Is this fuse labeled simply "Power Seat"? Please advise.

Technican: Excuse me but, did you intend to release this question before I even research it? I was hoping to FAX you graphics and troubleshooting charts...not good enough? If you release it again, I'll not interfere or try again. Can't please everyone everytime. Respectfully,

Owner: OK. Go ahead. I was hoping to get someone who had seen the same thing on another vehicle, but maybe that's not possible. You seem to be doing just what the dealer did, but I'll wait and see...

Technican: I would only hope to please you. If you would rather others step up, I'm fine with that. Just release your question again and I won't take offense. It's your call.

Owner: Give it a shot.

Technican: Thank you! Back today,

Owner: OK

Technican: I'm so sorry. When I got to the library a sign on the door said "Closed today while we move our computer automated control systems to the new library downtown". I had no idea...please forgive me. I had not expected this. There are two universities in close proximity to the library I use. The library is normally open everyday, and busy with student activities. (researching and studying.) Feel free to release the question. I'm without my resources for reasons beyond my control.

Technican: Hello again, I have the schematic for your power seat circuit. Fuse 1 (30amp), in the Central Junction Box, indeed is the fuse for the driver's power seat and no other system shares this fuse. Yours is a late production Explorer. I know this because Fuse 34 (30amp), in the Battery Junction Box, powers the passenger side power seat. Local Ford dealer here suggests that the switch for the driver's power seat be disconnected and the vehicle driven as needed for awhile to see if the Fuse 1 pops. If it does, the wiring is suspect between the fuse and the switch. If satisfied the days/distance driven for the above scenerio would have been long enough to expect the fuse to fail, the power seat switch itself is suspect for allowing a transient short or parasitic drain that over time develops enough heat to effect a "slow burn" amp draw that weakens the fuse until it finally fails. Disconnecting the seat motors and leaving the switch connected would not be a diagnostic step unless one of the motors felt warm to the touch. Would you like me to FAX the schematic to you? Would I need a cover sheet? Please advise.

Owner: I agree the switch is a prime candidate. How do I get at it? Also what about the other end? I cannot see underneath the fuse block but it looks like it comes out fairly easily - should I check the connections there?

Technican: To get to the switch the side trim needs to come loose from the seat cushion. There shows to be screws holding the trim to the seat base and the switch is fastened to the backside of the trim. If you have a FAX number I can send you an exploded view of the drivers seat that will help you see where you are going here. I suggest you disconnect the switch and drive the Explorer to see if the fuse stays good before you start tracing wiring. Truthfully, when technicians are unsure about the wire between the fuse and the switch they will run a new wire and cut the original wire loose but leave it in the harness to minimize consequence to appearance. If the driving of the vehicle doesn't pop that fuse with the seat switch disconnected, you have reason to believe your original wiring harness is perfect because there will be power on at all times. Rules of circuit protection are based on: a fuse is expected to pop if voltage gets to ground before arriving at a consumer/component where voltage drops because of load. That would be a dead short hands down. A popped fuse after the component's control device is relative to the component drawing too many amps, or the wiring/circuit between the control and the consumer is shorted to ground. Thoughts?

Technican: Hello, Please let me hear from you.

Owner: I haven't had time to deal with it. I might give the dealer one last chance now that I know it blows without using the seat. The vehicle is under an extended warranty and it should be covered.

Technican: Thank you. I sincerely hope they get the problem fixed for you.

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