SOLVEDThank you for the input Teztink.
What you said is correct. and I had already looked over the BEM board for bad contacts ,especially the relays.
The BEM does NOT stop the car when it is running. My problem was a BLACKOUT that left you sitting in the middle of the road.
TI performance that sell smartlock bypass modules state,
OTHER STARTING ISSUES
We often have people contact us about EA-AU Falcons that are not starting. Not all issues are smartlock related, for example:
No fuel pump – Smartlock does not affect the fuel pump.
No relays / ignition power – Smartlock does not cut ignition power.
Can randomly stops – Smartlock can not stop a running vehicle.
In these situations we suggest going over all fuses and relays to make sure everything is working. Also check all vehicle earths (battery to body and battery to block where fitted). So, to cut a very long story short, I finally went under the steering wheel and the fuse box. There is a thick YELLOW wire that goes from the back of the ignition lock assembly to a plug that is tied down in the most hard to reach location between the fuse box and the steering column. Focus on that thick gauge yellow wire!
I took apart that rectangular plug which has 6 (or 8?) female/male connectors. A close look at THE YELLOW FEMALE CONNECTOR (the part that connects the loom to the relays) showed that the metal clip that is crimped on the yellow wire was partly showing from the bottom of the connector. Yes, this wire was not sitting correctly and I had to use nose pliers and considerable force to push the wire crimp back in the connector so that it would mate with the male wire that is housed in the top part of the connector (the one that connects the wires to the ignition assembly). The ford ED has not faulted since!
This yellow wire connects to the green relay UNDER the wiper tank (NOT next to it) This wire was not pulled by mistake.....THE FLAW WAS PRESENT SINCE THE CAR WAS BUILT> This explains why many owners had the same problem. The connector and the loom was well bound to the steering rod by a metal clip which I had to open to access the connector. The car suddenly stops when you are driving along. Many concluded it was the Smartlock, NOT SO! The Smartlock cuts in because messing with that arcing yellow wire is equivalent to trying to hot wire the car. So the Smartlock cuts in.
This was a factory flaw. The person that made those connectors bacl in the early 90s must have had a bad day and did not insert the YELLOW wire properly in the case housing. maybe mine was a Friday car....
. And car hasn't ever cranked over so easily before like it does now, was quite surprised at the difference it has made.
!