Thunderbird Control Modules – ‘Ghost in the Machine’ – Your 2002-2005 Thunderbird won’t start, or sputters and quits, cranks but won’t turn over, or dies in the middle of the road. What’s the problem?
More and more 2002-2005 Thunderbird owners are learning the hard way about the consequences of defective electronic control modules. These modules are the ‘brains’ of most modern automobiles, and when they fail, your Thunderbird dies.
In the ‘old days’ cars were purely mechanical creations; engines, carburetors, spark plugs and distributors. Power windows, power steering and other ‘basic’ electronics relied on fairly simple wiring and common fuses. A good do-it-yourselfer could diagnose and repair most problems, and for those who couldn’t, the local mechanic could.
Today, modern cars and trucks are complex, ‘drive-by-wire’ technology-laden computers on wheels. They’re loaded with electronic control modules that are vital to nearly every function from fuel delivery, ignition, braking, lighting, steering, sound systems and nearly every power accessory found in the vehicle.
Needless to say, these electronic modules are vital to the operation of the modern car, and most newer cars and trucks have several of them, located throughout the vehicle, each managing multiple functions, systems and accessories.
For owners of the 2002-2005 Ford Thunderbird, electronic control modules pose an even greater threat than for most car owners … most are no longer available from Ford dealers.
More and more owners of the 2002-2005 Thunderbird are finding their cars inoperable and un-drivable, held virtual hostage by Ford dealers and repair shops waiting for parts that don’t exist. Dealers quote dates that come and go, production and availability postponed again and again, while disappointed owners wait for weeks or months, unable to drive and enjoy their Thunderbirds.
How could this happen with a car that’s only 10-13 years old? –
There are a number of reasons; First, the 2002-2005 Thunderbird is a very low-production vehicle. Only 68,095 built over four model years. That’s a tiny number of cars when compared to the hundreds of thousands of most models built every year. Low production numbers also means fewer OEM replacement parts, a situation made worse by Ford’s financial problems over a decade ago. The ‘Great Recession’ took its toll on U.S. automakers, and unlike GM and Chrysler, Ford did not take government bailout money. This meant even fewer replacement parts than would have otherwise been produced, along with the fact that many Ford suppliers went out of business and could no longer produce needed parts.
What can I do if my 2002-2005 Thunderbird needs a module that’s not available?
One option is to scour Ebay looking for the module you need. This can be a daunting task, especially if you don’t have a part number. Even if you do have the correct part number and know what you’re looking for, many online retailers including dozens of Ford dealers, will let you order and pay for a part, only to discover it is obsolete, out-of-production and no longer available. Another option is to search salvage yards and auto dismantlers. This can be even more difficult, as most salvage yards are not familiar with either the location or the part names and numbers of the control modules, and few offer any guaranty that they even work.
What about rebuilders and re-manufacturers?
There are companies that rebuilt, refurbish and remanufacture automotive electronic modules. Reliability and expertise of these companies varies widely. Finding a good one can be a challenge, and even then you’ll need both the correct part number and probably the ‘engineering number’ of the module in question. And that assumes you even know which of the half dozen or more electronic control modules your Thunderbird needs. Electronic control module problems are often mis-diagnosed. Sometimes a bad battery is the source of the problem. A weak or dead battery can cause a variety of electronic problems, and is easily replaced. But if you’re battery is good, you’ll need to dig deeper to uncover electronic problems. Fuses are inexpensive and easy to replace, if that’s the cause. But more often than not, the problem can be traced to a faulty electronic module.
How many electronic modules does the 2002-2005 Thunderbird have and which one do I need?
There are several electronic modules on the 2002-2005 Thunderbird including the FEM (front electronic module), ECM (engine control module), REM (rear electronic module, also known as the ‘Lighting Control Module’), PCM and more. Each controls a number of different functions including some that are vital to the operation of the Thunderbird.
Here’s a list of the various modules on the 2002-2005 Thunderbird:
Powertrain Control Module (PCM) – Among other functions, the PCM controls the automatic transmission solenoids.
Restraints Control Module (RCM) – Controls the front and side air bag supplement restraint system.
ABS Control Module – The ABS Control Module controls the anti-lock brake system. The ABS is a safety system that prevents your car from skidding or sliding when you apply the brakes. There are two main components: the ABS speed sensors and the ABS control module. When the brake is applied, the ABS control module reads the speed data from the speed sensor and sends the correct pressure to each wheel to prevent any sliding/skidding (wheels locking up).
If the ABS module or one of the sensors goes bad, the ABS warning light will turn on and it will disable the ABS. You will still be able to slow down and stop your car, but it will not prevent the wheel from sliding when you apply the brakes (especially critical on wet or slippery surfaces).
Front Electronic Module – The Front Electronic Module, or ‘FEM,’ controls the one-touch-down power driver’s window, the horn relay, and the exterior lighting at the rear of the vehicle.
Rear Electronic Module, also know as the ‘Rear Ambient Lighting Control Unit’ – Also known as the Rear Electronic Module, or ‘REM,’ controls the exterior lighting at the rear of the vehicle, the trunk release solenoid, and the passenger side power window. In the electronic returnless fuel injection system, the REM also controls the fuel pump on a pulse width command from the PCM.
Remote Keyless Entry Module
Instrument Panel Controller or IPC – The IPC not only controls the instrument cluster gauges and warning lamps, but also controls the electronic tilt and telescopic steering column.
Automatic Temperature Control Module, also known as a ‘DATCM,’ controls the heating and air conditioning functions.
In addition to these modules there are also three fuse/junction boxes: one located under the hood on the passenger side, one inside the cabin in the passenger side footwell, and one in the trunk inside the spare tire storage well.
My Thunderbird is at the Ford dealer or repair shop and they can’t get the module I need? What should I do?
First, ask your dealer if they have a firm date when the part will be available and get the part number of the defective module. If the dealer says there is no date when the part will be available it likely means that Ford or its suppliers won’t re-manufacture the part, ever. Ford outsources manufacturing of almost all automotive components to outside suppliers and vendors. Unless there is sufficient demand for a given part, it’s not cost-effective to do new production runs of a previously discontinued part. Aftermarket companies may decide to reproduce OEM Thunderbird parts in the future, but only if there’s enough demand to make it profitable, and that could be years from now.
I’ve tried everything to locate the need part with no success. What are my options?
In a worst-case scenario, you could sell or trade your Thunderbird, but if the car isn’t running you probably won’t get much for it. This just isn’t a realistic option for most Thunderbird owners.
The better option is to contact us. Powersport/Thunderbird Specialties can get any 2002-2005 Thunderbird control module your car needs. We offer remanufactured units, refurbished to Ford OEM specs and carry a one-year warranty. Better yet, our units are priced below Ford’s list price and you’ll receive a credit toward your purchase when you send us your defective module.
Get your Thunderbird out of the shop back on the road now! Call us at 310-589-1000 or send us a message using the ‘contact us’ form on this website. We’ll get your 2002-2005 Thunderbird running like new, and for less than you’ll pay your local Ford dealer.
For a much more comprehensive reference on automotive electronic modules, see the excellent book by Steve Hatch, ‘Computerized Engine Controls.’ This 740-page book is extremely detailed and includes many charts, diagrams, and specifications.
