One thing to check on the key ring..
Do you have another PATS key or a transponder ( like a mobil speed pass ) on the same ring ? Ford suggests not having other PATS keys or other transponders on the same ring, when starting a PATS enabled vehicle ( noted in the owners manual ).
If you are having the same problem, with just the key alone, I would think PATS reciever, not the PATS module itself.
The PATS module would need to be reprogrammed, so this is something that you are not going to be doing in your driveway ( need the dealer or a PATS locksmith to program the new keys ).
Have you tried testing the crank no start, with just the single key ?
When I had my Speed pass on the same ring, I would get a similar problem on occasion. I put this, and my hosue key on another ring. The starting that I learned to not have the symptom ( might not be the same as yours ) was to hold the ign key with my index finger and thumb, and hodl the RKE transmitter, and other key / speed pass in the palm of my hand with my pinky and ring fingers. Works 100% of the time on my '01, and now on my '06.
If you want to do a longer term test, just take off the PATS key, and use it by itself for a few days / weeks, to see if you have the same problem.
Last edited by SSCULLY; 06-02-2006 at 08:30 AM.