Engine Cut Out, Wont Start Will Start!

[FamilyWagon]

Driving down the motorway on Saturday and the engine just cut out. I pulled on to the hard shoulder and noticed the yellow transmission warning light was illuminated on the dash. I pulled the key out, then back in and then tried to restart the engine and it fired up immediately. I thought it was a bit strange but continued my journey until the next junction which was a services.

 

I pulled in to the services and had a nose under the bonnet. No loose wires and all the fuses were ok...and that's were my expertise ends.

 

I continued my journey and about 60 miles later the same thing happened, not fun when you are overtaking in the outside lane and you have your other half and 18 month old daughter on board.

 

Tried to restart it, turned the key and nothing happened.

 

Called the RAC via the Highways Agency on the roadside SOS phone and hid behind the barrier.

 

Got towed off the motorway and the Patrolman had a look.

 

The battery was fine, the fuses were fine and the cables were fine. He tested the starter and that was fine (with a separate piece of cable direct to the battery), but nothing happened when you turned the key. Then about 45 mins of him looking at it then bugger decided to start.

 

Continued my journey as I had a wedding to get to.

 

160 miles later and everything was fine, no sign of any problems.

 

I did a couple of short journeys on Sunday and everything was fine.

 

Then on the way home (280 miles) 60 miles in, just got on the M25, outside lane 70 - 75 mph (cruise control) same thing happens.

 

Pulled over, called RAC, hid behind the barrier, towed off, he had a butchers.

 

This time the yellow transmission warning light was not illuminated on the dash at all. The Patrolman attempted to get the fault code and his equipment would not connect to the ECU. So 7 hours and a big tow truck later the Galaxy (which is a 2003 2.3 DOHC Ghia) was outside my local Ford Dealer.

 

The dealer have now told me that there was no fault code when their equipment connected to it and that the car is running normally as they have taken it for a test drive. However they have reset the ECU and this should clear the problem as these things happen from time to time....apparently....they said!!!!

 

Does anyone have any idea what the problem is as it is clear that the dealer don't have a clue.

 

Any advice on how to handle the dealer would also be appreciated as this is the first run-in I have had with them and so far I am not impressed. If this fault can be found then I want it fixed while the car is still under warranty.

 

Thank you in advance of any help.

[Andrew T]

When you say "nothing happened" do you mean the dash lights came on but the starter wouldn't turn ?

 

By the "transmission light" do you mean the Orange engine fault warning light ?

 

Have you noticed if the LED on the drivers door flashes rapidly when the engine won't turn ?

[FamilyWagon]

When you say "nothing happened" do you mean the dash lights came on but the starter wouldn't turn ?

 

The dash lights did come on but the engine/starter motor did nothing.

 

By the "transmission light" do you mean the Orange engine fault warning light ?

 

Yes, the engine fault warning light - yellowy orange-ish colour.

 

Have you noticed if the LED on the drivers door flashes rapidly when the engine won't turn ?

 

I did not notice anything with the LED in the drivers door.

[Andrew T]

There have occasional reports of similar problems on 2.3 that have never reached any conclusion.

 

None starting combined with a flashing LED is an immobilisation fault (it disconnects the starter) but would not cause the cutting out (unless the immobiliser also disconnects the fuel pump).

 

On Mk1s relay 30 (K108 power relay) failing is a common fault, I'm told on the MK2 this function is covered by relay 27.

 

Also mentioned was an "intermittant Hall effect sender".

[FamilyWagon]

On Mk1s relay 30 (K108 power relay) failing is a common fault, I'm told on the MK2 this function is covered by relay 27.

 

Also mentioned was an "intermittant Hall effect sender".

 

What are these? Where can I find them? And how do I test them?

 

Also, if any of these were the problem, would/should it show any fault codes?

[Andrew T]

Relay 27 will be listed in your handbook, take it out and drop from about 12 inches onto a hard suface and that should unstick it. No idea about the Hall effect sender - it was a suggestion that member El Dingo made, you could try PM ing him.

[g4hlf]

Something similar happened to me recently......

 

50,000 miles of trouble free motoring without missing a beat I picked up my car from the garage after one of the many attempts to rectify my booster heater problem.

 

On the way out of the carpark it cut out on me and I did notice the red LED on the door flashing as well as hearing a muber of relay "chatter" at the same time. This happened a number of times on the way home, each time is stopped I was able to restart.

 

Driving along the Windsor relief road it died again and this time it was a little scary so I pulled over onto the verge and called the garage who sent the AA out to resue me!

 

The garage claimed it was a dodgy earth, it did make some sort of sence and I had checked the battery terminals as it sounded like electrical failure to me with the chattering relays.

 

Anyhow all is fine now.

 

Maybe checking the earths is worthwhile although I would have no idea where they are!

 

Paul