(SOLVED) PATS not programming keys

[dakar]

Brief back story, 2007 Ranger 3.0 for my teenage son. Lots of work done now running great. He's been 'practicing' awaiting the timer on his permit for his real license.

-Only came with one key (the keyring loop physically broken, but otherwise worked without issue).
-Ordered another key to add to the system. (I cut it on my old key machine, physically worked for doors and ignition)
-Verified the new key PID was 1601 so was expected to work.
-Using FORSCAN was able to delete all keys, even set other options like adding addtiopnal keys, unlimited keys, that sort of nonsense to ensure the system was working.
-NO keys are adding back in (including the original working), I beat on this for 6 hours and got nowhere.
-Called a mobile locksmith to come by (thinking maybe I'm stupid and doing something wrong), same results only faster as he was using Autel on a tablet so no security wait time. Even cut another key to see maybe mine was bad, still no joy. After an hour of trying different things he gave up.

Now I'm stuck with a truck stuck at the head of my driveway, showing 0 keys programmed, will not start or run and worse a rather disappointed but understanding young man.

Anyone got other ideas I can try before I call a wrecker to haul it to the stealership to rob me blind? This really shouldn't be such a chore, nor do i want to drop another $200-400 into something so minor as keys.

(Although, I have to admit I'm glad this happened now at home and not after he managed to lose the only working key while at school, work, or worse.)

 

[2011Supercab]

Make sure the trucks battery is fully charged, a low battery can sometimes mess with the PATS.

 

[dakar]

Make sure the trucks battery is fully charged, a low battery can sometimes mess with the PATS.

Battery was at 12.4 when I broke the world (slowly dropped to 12.3v through the day).
Charged back up to 12.4 overnight with a trickle charger.

 

[dakar]

I have it sorted now. Took a LOT more trial and error over another 3 hours.....

My Solution - It appears that in order to program new keys into the PCM from 0 keys registered, you must have Unlimited Keys disabled and/or you must disable the ability for User to add additional spare keys (one or both of these did the trick, I did them both at the same time out of frustration). Then go through the ignition key programming, Et Voilà! Both keys are registered and start the truck. No stealership trip needed!

I haven't seen this documented anywhere so maybe this will save someone time, frustration, and $$$ in the future.

 

[lil_Blue_Ford]

I know I had some issues with Forscan not liking battery voltage below 12.5v sometimes, actually got a low voltage error one time. Kinda weird.

Did not know about the unlimited key option though. Maybe it’s a newer thing. I always made sure I could add keys before deleting all of them, but definitely some good information that it can be finicky