The PATS module is in the instrument cluster on this vehicle, I'm sure the module is OK, sounds like you may have replaced or disconnected the cluster. You need to do a parameter reset in the PATS module and THEN KAM (Keep Alive Memory) reset in the PCM, This will re-push the VIN back to the instrument cluster. If you check the PID VIN_STORED it will say FALSE, Once you do the KAM reset cycle a key to ON position 3 times for 10 seconds each to make sure the VIN gets pushed. After this step go back into PATS and do a delete all keys and program. Once the second key is programmed, let it sit for 30 seconds with the key off before trying to start so programming will exit and you won't confuse the module. You normally don't have these issues with the PATS in the PCM but when it's in the cluster it's more temperamental, Let us know the outcome.

Thanks

 Hey, did the instructions I posted get you going?

Thanks

 I agree whole heartedly ! If Ford didn't have this function built in I wouldn't touch any ones but mine. Even a battery dying on you can cause issues like this. I seen one where a key would start a car one time and the next time it said it wasn't programmed to the car, Weird stuff ! After I replaced my battery I had an excessive voltage error in the 4WD module. They can be crazy ! Thanks for the follow up !