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No Start - PATS or something else?

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Old 06-21-2019
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No Start - PATS or something else?

THE BAD BEHAVIOR
When the intermittent no-start or failure occurs: (Both keys produce the same results)
The key switch it turned to the "ON" position, the PATS light continues to flash as if no key is present (once every 2 seconds indicating PATS is "armed"), the switch is turned to the "START" position, but no start activity. NOTE the PATS light is not flashing fast.

With the key turn to the "ON" position, all the warning icons light up except the engine light, and the PATS light continues to flash slowly. Most of the most of the lights go out as expected, the battery and oil lights remain on as expected. However, the PATS light continues to flash slow and the "4X4 LOW" remains on solid, but very dim and difficult to detect in daylight. Note: The "4X4 LOW" is next to the flashing PATS light on the dash panel. I would expect the 4X4 LOW to be off at this point. Maybe a SHORT?

Moving the gear selector to neutral does not improve the results.

THE WORK-AROUNDS
Waiting always works – let the truck sit from 5 minutes to several hours and the truck will start like nothing is wrong. The wait time varies and is not predictable.

Sometimes, I have been able to start the truck by rapidly moving the switch from "ON" to "START" and on about the 4th or 5th hit on "START", it starts. I have done this three times now. Again, this is not consistent. Moving the switch between ON and START normally doesn’t seem to do anything to help.

OTHER KNOWN INFO
All battery to starter connections have been clean and/or replaced a couple of times.
The starter has been replaced twice by a Ford Service Tech. The first time was to remedy the no-start issue, but the truck failed to start 3 days later with the same symptoms. The second replacement was due to the starter staying engaged for too long.

The transmission position sensor has been replaced by Ford Service, but the problem remains.

The after-market, non-Ford remote starter has been disconnected. Note the wiring remains installed, but the control box has been removed. Both Ford Service and the remote starter tech say this should not be causing the problem.

When the remote start was connected, the same symptoms and results described previously were experienced during a failed start.

The no-start has recently increased in occurrences, from once or twice a year to 2-3 times a week.
 
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