I found this TSB. It may/may not be of help. I'm not sure of the PCM being at fault because we seem to be getting good responses to the test's you perfrormed and we are still getting MIL @ KOEO. The light goes off @ cranking like it should and we are getting no codes. But now you have cranked it over a few times. With a no start. I would expect some sort of code to be popping up. It should be registering a fault with no start @ crank? I'm looking into the relay now?
ENGINE/TRANSMISSION DRIVEABILITY ISSUES
TECHNICAL SERVICE BULLETIN
Reference Number(s): 06-14-10, Date of Issue: July 24, 2006
FORD:1999-2003 Windstar; 2004-2007 Freestar
Superceded Bulletin(s): 05-23-7, Date of Issue: November 28, 2005
Related Ref Number(s): 05-23-7, 06-14-10
NOTE:This article supersedes TSB 05-23-7 to update the Service Procedure and model years.
Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts / engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area.
During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure.
Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Fig. 1 )
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Saturday, December 20th, 2008 AT 6:48 AM