2004 Ford Pickup F250 Super Duty

2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 104: Identifying Connector C2035

Courtesy of FORD MOTOR CO.

C:\Users\Shef\AppData\Local\Temp\mric_tmp\~od13B.jpg (2124 x 1622) @ 564.48px

Fig. 105: Identifying Connector C2041

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 70 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 106: Identifying Connector C2047, C2075 & C2089

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 71 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 107: Identifying Connector C2093, C2099 & C2110

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 72 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 108: Identifying Connector C2113a & C2113b

Courtesy of FORD MOTOR CO.

Fig. 109: Identifying Connector C2113c, C2116 & C2135

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 73 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 110: Identifying Connector C2142, C2159, C2160 & C2163

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 74 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 111: Identifying Connector C2176, C2194, C2207 & C2255

Courtesy of FORD MOTOR CO.

Fig. 112: Identifying Connector C2256, C2257, C2259 & C3002

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 75 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 113: Identifying Connector C3003, C3004, C3005 & C3007

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 76 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 114: Identifying Connector C3009, C3014, C3015 & C3044

Courtesy of FORD MOTOR CO.

Fig. 115: Identifying Connector C3049, C3084, C3085, C3086 & C3087
Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 77 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 116: Identifying Connector C3094, C3095 & C4000

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 78 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 117: Identifying Connector C4001, C4002, C4009 & C4010

Courtesy of FORD MOTOR CO.

Fig. 118: Identifying Connector C4011 & C4012

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 79 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

C:\Users\Shef\AppData\Local\Temp\mric_tmp\~od149.jpg (2124 x 1616) @ 564.48px

Fig. 119: Identifying Connector C4014

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 80 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 120: Identifying Connector C4015, C4032, C4033 & C4035

Courtesy of FORD MOTOR CO.

Fig. 121: Identifying Connector C4046, C4076, C4094, C4095 & C4096
Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 81 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 122: Identifying Connector C4097, C4098, C4099 & C4132

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 82 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Connector Views - Excursion & F250-F550 Super Duty Pickups

Fig. 123: Identifying Connector C9013

Courtesy of FORD MOTOR CO.

6 2013 . 19:49:35 Page 83 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

2004 ELECTRICAL

Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

IDENTIFICATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.

CENTRAL JUNCTION BOX

NOTE: Central junction box may also referred to as passenger compartment fuse
panel.

NOTE: Central junction box is located under driver's side of instrument panel. See
Fig. 1.

Fig. 1: Locating Instrument Panel Electrical Components

6 2013 . 19:04:45
19:04:38 Page 1 © 2011 Mitchell Repair Information Company, LLC.
 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Courtesy of FORD MOTOR CO.

Fig. 2: Identifying Central Junction Box Components

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 2 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 3: Central Junction Box Legend (1 Of 2)

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 3 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 4: Central Junction Box Legend (2 Of 2)

Courtesy of FORD MOTOR CO.

AUXILIARY RELAY BOX 1

NOTE: Auxiliary relay box 1 is located behind center of dash panel. See Fig. 5.

6 2013 . 19:04:38 Page 4 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 5: Locating Center Dash Panel Electrical Components

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 5 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 6: Identifying Auxiliary Relay Box 1 Components

Courtesy of FORD MOTOR CO.

AUXILIARY RELAY BOX 2

NOTE: Auxiliary relay box 2 is located in left rear corner of engine compartment.
See Fig. 7.

6 2013 . 19:04:38 Page 6 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 7: Locating Auxiliary Relay Boxes

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 7 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 8: Identifying Auxiliary Relay Box 2 Components

Courtesy of FORD MOTOR CO.

AUXILIARY RELAY BOX 3

NOTE: Auxiliary relay box 3 is located in left rear corner of engine compartment.
See Fig. 7.

Fig. 9: Identifying Auxiliary Relay Box 3 Components

Courtesy of FORD MOTOR CO.

AUXILIARY RELAY BOX 4

NOTE: Auxiliary relay box 3 is located in left rear corner of engine compartment.
See Fig. 7.

6 2013 . 19:04:38 Page 8 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 10: Identifying Auxiliary Relay Box 4 Components

Courtesy of FORD MOTOR CO.

AUXILIARY RELAY BOX 5

NOTE: Auxiliary relay box 5 is located in left rear corner of engine compartment.
See Fig. 11.

6 2013 . 19:04:38 Page 9 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 11: Locating Auxiliary Relay Box 5

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 10 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2004 ELECTRICAL Fuses & Circuit Breakers - Excursion & F250-F550 Super Duty Pickups

Fig. 12: Identifying Auxiliary Relay Box 5 Components

Courtesy of FORD MOTOR CO.

6 2013 . 19:04:38 Page 11 © 2011 Mitchell Repair Information Company, LLC.

 2004 Ford Pickup F250 Super Duty
2003-04 STARTING & CHARGING SYSTEMS Starters - Excursion & F250-F550 Super Duty Pickups - Gasoline

2003-04 STARTING & CHARGING SYSTEMS

Starters - Excursion & F250-F550 Super Duty Pickups - Gasoline

DESCRIPTION

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.

The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral
solenoid. Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission
Range (DTR) sensor (A/T), Clutch Pedal Position (CPP) switch (M/T), starter motor relay, and
interconnecting cables and wires.

COMPONENT LOCATIONS
COMPONENT LOCATIONS
Component Location
Central Junction Box Under Left Side Of Instrument Panel
Clutch Pedal Position On Clutch Pedal Bracket
Digital Transmission Range Sensor Left Side Of Transmission
Inertia Fuel Shutoff Switch Behind Passenger's Side Kick Panel
Starter Motor Relay In Central Junction Box

ADJUSTMENTS
DIGITAL TRANSMISSION RANGE SENSOR

1. Raise and support vehicle. Disconnect manual shift control cable from Digital Transmission Range
(DTR) sensor control lever. Disconnect DTR sensor harness connector. Place DTR sensor control
lever in Neutral. Loosen DTR sensor bolts.
2. Using DTR Sensor Alignment Tool (T97L-70010-A), align DTR sensor slots. Tighten DTR sensor
bolts to specification. See TORQUE SPECIFICATIONS. Place DTR sensor control lever in
Overdrive and connect shift lever control cable. Connect DTR harness connector.

TROUBLE SHOOTING
Verify customer compliant by operating starting system. Check battery for state of charge. Check cable
connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral (A/T).
Ensure clutch pedal is pressed down completely (M/T). On all models, check fuse No. 31 (15-amp) and fuse
No. 113 (30-amp) in central junction box. See Fig. 1. On M/T vehicles, check fuse No. 45 (10-amp). On all
vehicles, if problem is found, repair as necessary. If problem is not found, repair by symptom. See
SYMPTOM INDEX table under SYSTEM TESTS.

6 2013 . 19:53:58
19:53:55 Page 1 © 2011 Mitchell Repair Information Company, LLC.