'03 Exp XLT 2wd, 5.4l
Hello:
I have had my '03 Exp for about 9mns now--has about 11k mi. on it and runs great--(like my '99 F-150 XLT SC 4x4, 79k mi).
A month ago, I began hearing a tapping/chattering noise that sounds like an electrical relay going crazy. It sounds like it was coming from underneath the dash on the drivers side--it occurs intermittantly especially when going 30-40mph over bumps like lane divider dots on the road or ripples in the hiway. Took the car to dealer the first time, but could not get the noise to occur. A few days later, the noise started again and more frequently, so I took it back to the dealer. An electrical module that controls the brake lights was replaced since they found the brake lights were not functioning. This fixed the brake lights, but I found the dashboard lights would not change brightness when I rolled the dimmer dial up and down--the dash lights were just stuck on a low setting--note the headlights & headlight rotary switch worked. The dealer replaced the headlight/dimmer module. During a road test to located the source of the chatter noise, the technician found the "brake light relay" switch that attaches somewhere just underneath the dash, on the brake petal assembly was the cause for the noise(the switch is a black plastic rectangular box, one end is circular with a hole& size is about 3'L x 1"w x 0.25"D). During the road test, the tech found the back of the dimmer module very hot also. He said the faulty relay is probably the cause for blowing the brake light module and the dimmer control the prior week. So all the parts were now replaced, brake lights worked, and the dash lights/dimmer control functions, but the relay/ticking noise started again 2 days ago--the dash lights are out again. The brake lights are functioning so far as found after driving back home at night today.
Anyone experience this same problem and have an answer, know the diagnosis for this problem, or know what is causing the failures?
Thank you.
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