Test B: Engine Does Not Crank & Relay Does Not Click
WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Check Starter Motor Relay Coil For Voltage
Disconnect starter motor relay. Turn ignition switch to START position. Measure the voltage between the starter motor relay connector terminal No. 86 (White/Pink wire for A/T, Tan/Red wire for M/T) and ground while holding the ignition switch in the START position. See Figure. Is the voltage greater than 10 volts? If yes, go to step 7. If no, for A/T, go to step 4. For M/T, go to next step. - Check White/Pink Wire For Voltage At The Clutch Switch Or Jumper
Turn ignition off. Disconnect clutch pedal switch connector. Turn ignition switch to START position. Measure the voltage between the clutch pedal switch connector terminal No. 1 (White/Pink wire) and ground while holding the switch in the START position. See Fig 1. Is the voltage greater than 10 volts? If yes, go to next step. If no, go to step 4. - Check Tan/Red Wire For Open
Turn ignition off. Measure the resistance between the clutch pedal switch connector terminal No. 2 (Tan/Red wire) and the starter motor relay connector terminal No. 86. See Figure and Fig 1 . Is the resistance less than 5 ohms? If yes, install a new clutch pedal switch. See CLUTCH PEDAL POSITION (CPP) SWITCH under REMOVAL & INSTALLATION. Test the system for normal operation. If no, repair Tan/Red wire between clutch pedal switch and starter motor relay. See WIRING DIAGRAMS . Test the system for normal operation. - Check For Voltage At Fuse No. 31
Turn ignition off. Disconnect fuse No. 31. See Figure. Turn ignition to START position. Measure the voltage between the central junction box fuse No. 31 (15-amp) (Dark Green wire) and ground while holding the ignition switch in the START position. Is the voltage greater than 10 volts? If yes, repair White/Pink wire between fuse No. 31 and starter relay. See WIRING DIAGRAMS . Test the system for normal operation. If no, go to next step. - Check Light Green/Violet Wire For Voltage
Turn ignition off. Disconnect ignition switch connector. Measure the voltage between the ignition switch connector terminal B4 (Light Green/Violet wire) and ground. See Fig 2. Is the voltage greater than 10 volts? If yes, go to next step. If no, check fuse No. 116 (30-amp) in central junction box. See Figure. If fuse is okay, repair Light Green/Violet wire between fuse No. 116 and ignition switch. See WIRING DIAGRAMS . Test the system for normal operation. - Check The Ignition Switch
Perform the ignition switch component test. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Does the ignition switch test good? If yes, repair Dark Green wire between ignition switch and fuse No. 31. Test the system for normal operation. If no, install a new ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Test the system for normal operation. - Check Relay Ground Circuit For An Open
Measure the voltage between the starter motor relay connector terminal No. 85 (Black wire for M/T, Brown/Pink wire for A/T) and terminal No. 86 (Tan/Red wire for M/T, White/Pink wire for A/T) with the ignition switch in the START position. See Figure. Is the voltage greater than 10 volts? If yes, install a new starter motor relay. Test the system for normal operation. If no, for M/T, repair Black wire between starter relay and ground. See WIRING DIAGRAMS . Test the system for normal operation. For A/T, go to next step. - Check Brown/Pink Wire
Turn ignition off. Disconnect PCM connector C1381a. Measure the resistance between the starter motor relay socket connector terminal No. 85 (Brown/Pink wire) and the PCM connector C1381a terminal No. 4. See Figure and Fig 3 . Is the resistance less than 5 ohms? If yes, install a new PCM. Test the system for normal operation. If no, repair Brown/Pink wire between starter relay and PCM. See WIRING DIAGRAMS . Clear the DTCs. Test the system for normal operation.