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Old 06-22-2013, 17:24   #1 (permalink)
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2003 Ford F-150 Horn Issues

All,

I replaced the OEM horn on my 2003 F-150 several years ago after the OEM horn stopped working.

I replaced the OEM horn with a Wolo Bad Boy horn and it has worked great for about 4 years. The Wolo horn recently stopped working and I have attempted to replace it with yet another Wolo Bad Boy horn, same exact model. I used the same relay from the previous install.

I connected everything as before and noticed that the horn was loud, but not quite as loud as the previous one. I thought that maybe the relay was not working properly, so I replaced the old relay with the new one that came in the package with the new Wolo Bad Boy horn.

I connected everything and the horn does not work at all. I switched the connections around and cannot get this damn thing to work.

I have confirmed that the relay works using a benchtop power supply and my digital multi-meter.

Furthermore, I have confirmed that the Wolo Bad Boy horn works by connecting it directly to the battery for a few moments.

I connected my digital multi-meter to the terminals on the original horn wires. When I press the horn button on the steering wheel, should this close the circuit and BEEP for continuity? In fact, doesn't my F-150 already have a relay to handle this. I am not really even sure why I need a secondary relay.

Anyway, no beep on my multi-meter. When I switch to voltage or current, I just get zeros. I think that the problem is with my horn button on the steering wheel.

So essentially I now have no horn. Any thoughts? Is this something that I can replace without messing with the airbag? Thanks in advance.
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Old 06-22-2013, 17:39   #2 (permalink)
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Re: 2003 Ford F-150 Horn Issues

The yellow/green wire to the original horns should have 12v when the horn button is pressed. Here's the diagram for it. | Repair Guides | Horn & Cigarette Lighter (2003) | Horn & Cigarette Lighter (2003) | AutoZone.com
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Old 06-22-2013, 19:16   #3 (permalink)
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Re: 2003 Ford F-150 Horn Issues

Thanks Bert. I wonder if the horn relay in the junction box is "fried". I may remove the relay and test it with my benchtop power supply and digital multi-meter. So I probably don't need the additional relay if there is already a relay in the system. I never thought about that before today.

I have also done a bit more research since my last post, and I am wondering if I may need to replace the horn pad. It appears that you have to purchase the airbag and horn pad as a single assembly for lots of $$$.

Thanks,
Neal
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Old 06-22-2013, 19:38   #4 (permalink)
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Re: 2003 Ford F-150 Horn Issues

Dear Bert,

I just popped the cover off of the fusebox. I cannot identify which relay controls the horn. Would this relay be located in the fusebox, or would this be located in the junction box?

I looked in the owners guide for a fuse/relay chart, and the tables do not specify locations for relays...only fuses.

I have a 2003 F-150 2wd with a 4.2L V6.

I have attached photos of both my fusebox and junction box.

Thanks.
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Old 06-22-2013, 20:48   #5 (permalink)
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Re: 2003 Ford F-150 Horn Issues

Okay. So I identified 205 as the horn relay in the junciton box. I will remove the relay in the morning to determine whether or not this is what has failed. I can likely swap out one of the other identical relays in the junction box to test my theory. I can also insert the leads of my digital multi-meter into the slots of the junction box to see if the switch is functioning properly without removing the horn pad. What do you think?
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Old 06-22-2013, 21:33   #6 (permalink)
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Re: 2003 Ford F-150 Horn Issues

Sounds like you're right on. That link I sent shows the whole set of diagrams. Check the left column.
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Old 06-24-2013, 16:16   #7 (permalink)
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Re: 2003 Ford F-150 Horn Issues

PROBLEM SOLVED!!! I Figured out which fuses and which relays control the horn. I swapped out identical relays to see if maybe I had a bad relay. This did not fix the problem.

I then started to examine the fuses in the junction box (under the hood). Originally, I did not realize that the horn fuse was in the junction box and not in the fuse box (in cockpit). There were only four 20A fuses (if I recall correctly) in the junction box, so after putting the relays back where they belong, I started pulling 20A fuses. Low and behold, the 3rd one that I pulled was "fried". I must have shorted one of the terminals when I was installing the horn this past weekend.

I am very relieved that I do not have to start messing with the horn pad/airbag assembly and that I will not have to incur the big expense $$$...at least not yet.

The new Wolo Bad Boy horn works great!!!

Thanks,
Neal
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Old 06-24-2013, 18:55   #8 (permalink)
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Re: 2003 Ford F-150 Horn Issues

That's great to hear. Thanks for the update.
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