Starter Does Not Crank But Relay Clicks
- Turn ignition switch to OFF position. Remove and inspect fuse No. 8 (30-amp) in battery junction box. If fuse is okay, verify battery condition. Replace fuse if blown. If fuse blows again check circuit for short to ground. See WIRING DIAGRAMS
. Restore electrical connections and retest system operation. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary. If battery is okay, go to next step.
- Turn ignition switch to OFF position. Remove starter relay from central junction box. Connect a jumper wire between positive battery terminal and starter relay terminal No. 2. Connect another jumper wire between negative battery terminal and starter relay terminal No. 1. Measure resistance between starter relay terminals No. 3 and 5. See Figure
. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, replace relay. Restore electrical connections and retest system operation.
- Remove starter relay, located in central junction box. Measure voltage between starter relay harness connector terminal No. 3 and ground. If voltage is greater than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Gray/Orange wire. Restore electrical connections and retest system operation.
- Ensure ignition is off. Disconnect starter motor 16-pin in-line connector. Measure resistance of Gray wire between terminal No. 12 at starter motor 16-pin in-line connector and terminal No. 5 at starter relay. See Figure
and Fig 1
. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Gray wire between starter motor 16-pin in-line connector and starter relay. Restore electrical connections and retest system operation.
- Connect starter motor 16-pin in-line connector. Install starter relay. Measure voltage drop between terminal "B" (component side) and positive battery terminal, with ignition switch in RUN position. If voltage drop is less than .5 volt, and vehicle is equipped with automatic transaxle, go to next step. If voltage drop is less than .5 volt, and vehicle is equipped with manual transaxle, repair open in Gray wire between starter relay and starter motor. Restore electrical connections and retest system operation. If voltage drop is greater than .5 volt, clean and tighten all positive battery terminals. Restore electrical connections and retest system operation. If fault is still present, replace positive battery cable.
- Disconnect Transmission Range (TR) sensor harness connector C438. Measure resistance between terminals No. 6 (Gray/Red wire) and No. 9 (Gray wire) component side in park and neutral at TR sensor. See Fig 2
. If resistance is 5 ohms or less, repair open in Gray wire or Gray/Red wire. See WIRING DIAGRAMS
. Retest system operation. If resistance is greater than 5 ohms, adjust TR sensor. If fault is still present, replace TR sensor. Restore electrical connections and retest system operation.
Courtesy of FORD MOTOR CO.
Courtesy of FORD MOTOR CO.