The dreaded PATS system on a 2004 Exp

I suspect I’m having trouble with my PATS also - and my 2007 Expy has been stripped down to a roller/camper (removed front end, powertrain, drivetrain, dash, seats, etc) that I plan to tow as a sleeper/camper. I decided to NOT rewire everything, since the fuses/relays in the BJB and SJB give me about 99% (still no SJB power to 5A “radio” fuse #28 for some reason) of what I want (window operation, lights, etc) with just a few jumpers. I hear the internal relays clicking on/off in the SJB which I assume is the PATS going haywire, but not sure how to disable. I may expose the PCB of the SJB and see if I can solder something to kill the annoying clicking sounds.

The only time I experienced the rapid clicking of relays in mine the locks were going nuts and the horn decided to announce my arrival at work haha. Can't remember if there was more. Anyway, the resolution was to remove the dielectric grease that my son had put on the battery terminals. So it's possible the issue is as simple as dirty battery terminals or a ground issue.

Very interesting project you have there.

Well, I hope I'm not cursing myself by saying this, but after my last dealership visit, it seems as though it wasn't really the PATS thing after all, but rather a series of 4 different relays that failed one after the other, each one of which caused the no-start/flashing padlock issues.

According to the svc mgr, the flashing padlock is the only way for several other systems (ECU, TCU, starter etc) to alert you to a problem.....

So with fingers crossed, my Expy is finally starting reliably every time now for over a month and hopefully that is the end of that nonsense....

I had looked into the FORESCAN thing, which would have been/is gonna be my next step if any other issues pop up, I just wish I'd known about it sooner, before so many trips to & time at the dealers and spending $3K that I could have used for other things !

Thankfully I have a AAA membership, so the tows to the shops didn't cost me anything, so there's that