2005 ford freestyle will fuse # 40 in the underhood fuse panel when the key is turned to the run/start position. It would blow before when it was running and cause a rough running condition. Could it

Fuse Box Diagram Ford Freestyle (2005-2007) - Fuse-Box.info

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Fuse box diagram (location and assignment of electrical fuses and relays) for Ford Freestyle (2005, 2006, 2007).

Ford Freestar (2003 - 2007) - fuse box diagram - Auto Genius

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Jul 8, 2018 - Ford Freestar (2003 - 2007) - fuse box diagram. Year of production: 2003, 2004, 2005, 2006, 2007. Passenger Compartment Fuse Panel.

Under-hood fuse box diagram: Ford Freestyle (2005) - Pinterest

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Apr 5, 2019 - Fuse box diagram (location and assignment of electrical fuses and relays) for Ford Freestyle (2005, 2006, 2007).

Any applicable trouble codes? Several systems get voltage off that same fuse. oxygen sensors-- canister purge solenoid--ac compressor relay--imrc, intake manifold runner control, has to do with induction-- breathing. And tranny control.
If it blows as soon as the key is turned on, maybe you can narrow it down by unplugging each system one at a time? That may not be conclusive, any system you unplug, there will be less amp draw on the fuse. Just a thought.

Underhood fuse box

press the helpful button,there appears there is more then one type of remote, I think one has auto start and one does not.

owners manuals in the glove box and in there was the Ford Auto Start Remote booklet. For those of you who need to program a new auto start remote, you turn the ignition to the on position, push and hold the little over-ride button (mine is down on the left side kick plate near the hood release) for about 15 seconds, you will hear a chirp which means the system is ready to be programmed, just hit the lock key on your remote and the system will chirp acknowledging the remote has been programmed, continue to do this will all other remotes you have within I believe it was 20 seconds - then shut off the ignition and test your remotes. Worked perfectly for me.
OR

Free Do It Yourself instructions from your friends at Lessco Electronics

1. Turn ignition from OFF to RUN 8 times within 10 seconds, with the 8th time ending in RUN. Door locks will cycle to confirm programming mode.

2. Within 20 seconds press any button on first keyless remote. Door locks will cycle to confirm programming.

3. Within 20 seconds, press any button on second keyless remote. Door locks will cycle again to confirm programming.

4. Turn ignition to OFF. Locks will again cycle to indicate end of programming mode.
Link below
2005 2006 Ford Freestyle Factory Transmitter Remote Fob Programming

There is a short somewhere in the wiring to the devices supported by that fuse. Tis may be hard to track down, but I would start at the driver's window controls and wiring inside of that door.

The stem like fixture is called a schreader valve and it looks like a car tire air stem. It's on the fuel rail. So from your injectors trace back to the main line then follow that back until you fine the valve. Most fuel pump are good for around 80k - 100k before they fail. I would press the valve and see if you have fuel come out first. Insert key in ign. turn to on position (Wear safety goggles) then press valve. If gas shoots out It's probably not you pump. If it doesn't have gas come out then I'd check the fuse center under the hood and check the fuel pump replay fuse to see if it's good. Check the fuel pressure regulator also and check to make sure you have spark going to your plugs. Maybe your CPS (Cam or crank position sensor) went out.

You have a short in that wiring, most likely related to your starting motor. Pull the starter relay (in the underhood fuse box) and try a new fuse to see if that is the case. If so you will need to have the motor checked. If not, there are a variety of systems that use this feed via the ignition switch and each will have to be checked (including the switch). If you need a wiring diagram, try Alldatadiy.com.

The 40 amp maxi fuse in the underhood junction block (According to the information I have, there is only one 40 amp fuse in there..) goes directly to the ignition switch. From there, it goes to the buss bar in the Instrument Panel Fuse Block where it feeds several smaller fuses. It also feeds the starter relay in the Underhood Fuse and Relay Center.

My biggest concern would be: What caused the fuse to blow in the first place?

If you get nothing else from my preaching, get this:

Fuses don't blow for no reason....ESPECIALLY not a 40-amp Maxi Fuse!

I can't count how many times I have heard people say: "It's JUST a blown fuse." WHAT???

I have been at this for 35 years and I can tell you that blown fuses are reason for major concern in my book. That 40-Amp Maxi Fuse just saved your truck from burning to the ground and you need to find out why!

The only way that fuse is going to blow is if there is a direct short to ground between the Underhood Fuse and Relay Center and the Instrument Panel Fuse Block (The only "component" between these two is the ignition switch.) or if the secondary side of the starter relay circuit is shorted to ground. The secondary side of the starter relay feeds the "S" terminal of the starter solenoid. (at the starter)

I think the first place I would look for the problem would be the circuit between the starter relay and the starter. It is likely to be shorted against the exhaust or engine block. If this is the case, it most likely fried the starter relay in the process. (which is why the fuse no longer blows and the engine no longer starts)

Aftermarket remote starting units are also usually tied into this circuit. If your vehicle has one of these, it could very likely be the original source of your problem.

At any rate, there should be no rest, truck running or not, until the reason for the blown fuse is found. You will most likely get the truck running in the process of locating the reason for the blown fuse.

What engine size? Underhood Fuse Block 4.2L Engine Except Saab Underhood Fuse Block (2002 - 2005 Early Production)

Underhood Fuse Block (2005 Late Production - 2007)

Saab Underhood Fuse Block (2005)

Underhood Fuse Block (2005 - 2007)

5.3L Engine Except Saab Underhood Fuse Block (2003 - 2005 Early Production)

Saab Underhood Fuse Block (2005)

Underhood Fuse Block (2006 - 2007)

5.3L & 6.0L Engines Except Saab Underhood Fuse Block (2005 Late Production - 2007)

Sounds like ignition relay.