Test A: Engine Does Not Crank & Relay Clicks
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2003 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
- Check The Voltage To The Starter Relay
Measure the voltage between the starter relay connector terminal No. 30 (Red wire) and ground. See Fig 1. Is the voltage greater than 12.5 volts? If yes, go to next step. If no, check fuse No. 113 (30-amp) in central junction box. If fuse is good, repair Red wire between central junction box and Gray fusible links. See WIRING DIAGRAMS . Test system for normal operation. - Check The Voltage To The Starter Motor Solenoid
Measure the voltage between the starter motor solenoid "B" terminal and ground. See Fig 2. Is the voltage 12.5 volts or greater? If yes, go to next step. If no, repair Red wire between starter solenoid and battery for an open. See WIRING DIAGRAMS . TEST the system for normal operation. - Manually Jump The Starter Motor
Connect one end of a fused jumper wire (15A) to the positive terminal of the battery and touch the other end to the starter solenoid "S" terminal. See Fig 2. Does the starter solenoid engage? If yes, go to next step. If no, install a new starter. Test the system for normal operation. - Test The Starter Motor Relay
Carry out the relay component test on the starter motor relay. See STARTER RELAY under COMPONENT TESTS. Does the starter motor relay test good? If yes, repair Yellow/Light Blue wire between starter relay and starter solenoid for an open. See WIRING DIAGRAMS . Test the system for normal operation. If no, install a new starter motor relay. Test the system for normal operation.