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Test B: Engine Does Not Crank & Relay Does Not Click

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove fuse No. 111 (40-amp) in battery junction box. Check continuity of fuse No. 111. If fuse No. 111 is okay, reinstall fuse and go to next step. If fuse No. 111 is open, install new fuse and go to step  15.
  2. Remove fuse No. 21 (15-amp) in central junction box. Check for continuity of fuse No. 21. If fuse No. 21 is okay, reinstall fuse and go to next step. If fuse No. 21 is open, install new fuse, and go to step  18.
  3. Measure voltage between ground and input side of central junction box fuse No. 21 while holding ignition switch in START position. If battery voltage is present, go to step  6. If battery voltage is not present, go to next step.
  4. Disconnect ignition switch 15-pin connector. Measure resistance in Red/Light Blue wire between input side of central junction box fuse No. 21 and ignition switch connector terminal STA. See Fig 1. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Red/Light Blue wire between ignition switch and central junction box. See WIRING DIAGRAMS . Check system operation.
    Fig 1: Identifying Ignition Switch Connector Terminals
    G98G01757Courtesy of FORD MOTOR CO.
  5. Remove battery junction box fuse No. 111 (40-amp). Measure resistance of Light Green/Violet wire between ignition switch harness connector terminal B5 and output side of battery junction box fuse No. 111. See Fig 1. If resistance is less than 5 ohms, replace ignition switch. See STEERING COLUMN SWITCHES - F150 PICKUP article in ACCESSORIES & EQUIPMENT. If resistance is 5 ohms or greater, repair open in Light Green/Violet wire between ignition switch and battery junction box. See WIRING DIAGRAMS . Check system operation.
  6. Turn ignition switch to LOCK position. Disconnect starter motor relay connector (Tan/Red wire). Measure voltage between ground and Tan/Red wire at starter motor relay connector terminal while holding ignition switch in START position. If battery voltage is present, replace starter motor relay. Check system operation. If battery voltage is not present, go to next step (A/T models) or go to step  12 (M/T models).
  7. Disconnect Digital Transmission Range (DTR) sensor 12-pin connector. Measure resistance of Tan/Red wire between DTR sensor connector terminal No. 12 and starter motor relay connector. See Fig 2. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Tan/Red wire between DTR sensor and starter motor relay. See WIRING DIAGRAMS . Check system operation.
    Fig 2: Identifying Digital Transmission Range Sensor Connector Terminals
    G98F01752Courtesy of FORD MOTOR CO.
  8. Check DTR sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR  under ADJUSTMENTS. If DTR sensor is adjusted properly, go to next step. If DTR sensor is not adjusted properly, adjust as necessary. Check system operation.
  9. Connect a jumper wire between DTR sensor connector terminals No. 12 (Tan/Red wire) and No. 10 (Dark Blue/Orange wire). See Fig 2. Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace DTR sensor. See DIGITAL TRANSMISSION RANGE SENSOR  under REMOVAL & INSTALLATION. Check system operation.
  10. Disconnect Clutch Pedal Position (CPP) jumper 6-pin connector. Measure resistance of Dark Blue/Orange wire between DTR connector terminal No. 10 and CPP jumper connector terminal No. 2. See Fig 2 and Fig 3 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Dark Blue/Orange wire between DTR sensor and CPP jumper. See WIRING DIAGRAMS . Check system operation.
    Fig 3: Identifying Clutch Pedal Position Switch Or Jumper Connector Terminals
    G98A01759Courtesy of FORD MOTOR CO.
  11. Measure resistance between CPP jumper terminals No. 1 and 2 (component side). If resistance is 5 ohms or less, go to step  14. If resistance is greater than 5 ohms, replace CPP jumper. Check system operation.
  12. Disconnect starter motor relay connector (Tan/Red wire). Disconnect CPP switch 6-pin connector. Measure resistance between Tan/Red wire at starter motor relay connector terminal and CPP switch connector terminal No. 2 (Dark Blue/Orange wire). See Fig 3. If resistance is less than 5 ohms, reconnect starter motor relay and go to next step. If resistance is 5 ohms or greater, repair open in Tan/Red wire or Dark Blue/Orange wire between CPP switch and starter motor relay. See WIRING DIAGRAMS . Check system operation.
  13. Connect a jumper wire between CPP switch connector terminals No. 5 (White/Pink wire) and No. 6 (White/Pink wire). Connect another jumper wire between CPP switch connector terminals No. 1 (White/Pink wire) and No. 2 (Dark Blue/Orange wire). See Fig 3. Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace CPP switch. Check system operation.
  14. Disconnect central junction box Black 34-pin connector C243. Measure resistance of White/Pink wire between central junction box connector C270B terminal No. 29 and CPP switch/jumper connector terminal No. 1. See Fig 3 and Fig 4 . If resistance is less than 5 ohms, replace central junction box. If resistance is 5 ohms or greater, repair open in White/Pink wire between central junction box and CPP switch/jumper. Check system operation.
    Fig 4: Identifying Central Junction Box Connector C270A&B Terminals
    G00281075Courtesy of FORD MOTOR CO.
  15. Momentarily turn ignition switch to START position. Turn ignition switch to LOCK position. Remove fuse No. 111 (40-amp) from battery junction box. Check fuse for open. If fuse is open, go to next step. If fuse is okay, system is okay at this time.
  16. Disconnect ignition switch connector. Measure resistance between ground and ignition switch connector terminal B5 (Light Green/Violet wire). See Fig 1. If resistance is greater than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Light Green/Violet wire between ignition switch and battery junction box. See WIRING DIAGRAMS .
  17. Remove fuse No. 21 (15-amp) from central junction box. Measure resistance between ground and ignition switch connector terminal STA (Red/Light Blue wire). See Fig 1. If resistance is greater than 10 k/ohms, replace ignition switch. Check system operation. If resistance is 10 k/ohms or less, repair short to ground in Red/Light Blue wire between ignition switch and central junction box. See WIRING DIAGRAMS .
  18. Turn ignition switch to START position. Turn ignition switch to LOCK position. Remove and recheck fuse No. 21. If fuse is not open, no problem is indicated at this time. If fuse is open, install new fuse and go to next step.
  19. Disconnect starter motor relay connectors. Turn ignition switch to START position. Turn ignition switch to LOCK position. Recheck fuse No. 21. If fuse is okay, replace starter motor relay. Check system operation. If fuse is open, install new fuse and go to next step.
  20. Disconnect CPP switch or CPP jumper connector. Measure resistance between ground and CPP switch/jumper connector terminal No. 1 (White/Pink wire). See Fig 3. If resistance is greater than 10 k/ohms, go to next step (A/T) or go to step  24 (M/T). If resistance is less than 10 k/ohms, repair short to ground in White/Pink wire between CPP switch/jumper and central junction box. See WIRING DIAGRAMS . Check system operation.
  21. Place transmission in Park. Measure resistance between ground and Tan/Red wire at starter motor relay connector terminal . If resistance is 10 k/ohms or less, go to next step. If resistance is greater than 10 k/ohms, replace CPP jumper. Check system operation.
  22. Disconnect DTR sensor connector. Measure resistance between ground and DTR sensor connector terminal No. 10 (Dark Blue/Orange wire). See Fig 2. If resistance is greater than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Dark Blue/Orange wire between DTR sensor and CPP jumper. See WIRING DIAGRAMS . Check system operation.
  23. Measure resistance between ground and DTR sensor connector terminal No. 12 (Tan/Red wire). If resistance is greater than 10 k/ohms, replace DTR sensor. Check system operation. If resistance is 10 k/ohms or less, repair short to ground in Tan/Red wire between DTR sensor and starter motor relay. See WIRING DIAGRAMS . Check system operation.
  24. Disconnect starter motor relay connectors. Measure resistance between ground and CPP switch connector terminal No. 2 (Dark Blue/Orange wire). See Fig 3. If resistance is greater than 10 k/ohms, replace CPP switch. Check system operation. If resistance is 10 k/ohms or less, repair short to ground in Tan/Red wire between CPP switch and starter motor relay. See WIRING DIAGRAMS . Check system operation.
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