Sorry, I may have posted this in an incorrect catagory earlier so here goes.....
Two plus year issue. Much frustration and much money spent. Think my ignorance is being taken advantage of....PLEASE HELP!!
Bought truck Feb 2016. Very clean with 196+K miles. Aug/ Sep it started. I'll try and just stick with the facts and timeline to see what you guys think. I've had it am at wit's end and out of money to throw at it. I work helo's I don't know diesels nor automotive electronics.
1. Fall 2016 driving to work in rain. Wipers stopped. on side of road also saw the cluster was dead all gages dropped, odometer blank, no stereo, no heat or pwr windows ABS and couple other warning lights came on. engine and trans still functioned. Called a Ford specific shop closest to home. As I was talking with them, everything sprang back to life. Dropped at the shop. Kept it a week saying they couldn't duplicate. Finally they said the cluster was bad. Had replaced. Issue went away for a period of time

2. Several months problem free then same symptoms returned. tolerated it a while before having checked.
SIDENOTE Once in a while, randomly, between earlier episodes I'd notice the ABS light randomly come on some start-up sequences and stay on a while but eventually go back off....figured dirty sensor or something. Braked never have had issues. Do need replacing now with 345K mi.....
Back to #2. Had it checked.......bad body computer. Had it replaced. Issues went away for some time then came back, identical every time as the first symptons. This time I was told it was a loose wire behind the stereo. I called BS this time. Told them I was sick and tired of paying them to learn how to troubleshoot and refused to pay the $275 "wire repair" (Beginning to wonder just how much they looked for or got it to duplicate symptoms....) and they zeroed the bill.

3. Feb Record low temps in N.C. Even with heater plugged in, both batteries die. Retailer warrantied both. Replaced all but one of the stock flimsy factory batt end terminals with heavy duty gold plated ones that had holes and set screws to secure wires. Stripped back and saw noting but bare clean copper on the main batt cables. Installed, heat shrinked ends and she fired right up and has ever since.

4. May this year. same prob returns. Some time passes and back it comes again. Back to shop very irate having spent time and money to no avail and screaming refund and warranty. After a day or so they say the alternator is bad although NO other electrical issues. Replaced Alt. been operating as normal until....... Cranks right up every time. I When I picked it up and paid that bill I saked what would they draw from the hat to blame it on when it happens next time as they've replaced every expensive part in the system......

5. 2 weeks ago. Driving home from work ABS light caught my eye.) Know and already have rotors and pads for changeout first warm day). As I scan, all the symptoms are back. Called shop livid! Also noticed the "off" light in the shift lever for the overdrive was flashing. As I was driving and talking with them, as in the past, suddenly everything came back alive.....
Dropped off next morning (Last Wed). Had to chase them down for updates but never got a call from them. "We're still looking into it We'll let you know...." gave them "what for" each time I called about incompetence, etc, failing to diagnose for 2 years and just throwing parts at it. Monday they call and say the found it ( again?!?!?!?). it's the battery cables, they're corroded. they need replaced to the tune of $6-700 parts/ labor.
Unless they stripped off the insulation how would they know?
If the ends are corroded wouldn't cleaning the bare terminal; ends to a point rectify that???
Best I know, that should have caused all sorts of CRANKING problems since those heavy cables are mainly for the starting sequence and in addition to A/C loads the Alt would replenish battery drains from the DC systems in the truck. I've never had any sort of starting/ hard to start or needs a jump since I replaced the batteries and term ends. A mechanic told me that a bundle of wires that runs across top of the left fender well contains come ABS wires and sometimes that bundle can chafe and that the abs wires can cause the cluster and other symptoms I have been experiencing.
I told them not to do anything to the truck, that I'd be by to pick it up along with detailed reports of what they troubleshot each time but most especially this last one. I plan on checking the wiring bundled under the filter box as well as plugging and unplugging every plug to rub-clean as well as clean every terminal end and such. I have no clue how to win this battle I'm pondering with the shop. Has anyone ever won in small claims? Are there advocacy groups or any avenues I might try for restitution thtough and has anyone had anything similar and figures out what the root problem was? Thanks
Dave