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Test A: Engine Does Not Crank Or Relay Clicks

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  1. Ensure starter motor is tightly mounted. Verify battery condition. 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.
  2. Inspect battery ground cable connection on starter motor. Repair as necessary. If battery ground cable is okay, measure voltage between positive battery cable connection at starter motor and ground. If battery voltage is present, go to next step. If battery voltage is not present, perform VOLTAGE DROP TEST  under ON-VEHICLE TESTING. Repair or replace positive cable or connections as necessary.
  3. Measure voltage between starter motor solenoid terminal "S" and ground with ignition in START position. See Fig 1. If battery voltage is not present, go to next step. If battery voltage is present, clean and tighten Red wire connections at starter motor and relay and check system operation. If starter motor still does not crank, replace starter motor. See STARTER MOTOR  under REMOVAL & INSTALLATION.
    Fig 1: Identifying Starter Motor Solenoid Terminals
    G98J12277Courtesy of FORD MOTOR CO.
  4. Measure voltage between each Red starter motor relay wire and ground. Battery voltage should be present at one Red wire with ignition off. Battery voltage should be present at both Red wires with ignition switch in START position. If voltage is as specified, repair open in Red wire between starter motor relay and starter motor. See WIRING DIAGRAMS . If battery voltage is present on only one Red wire with ignition switch in both OFF and START positions, go to next step. If battery voltage is not present at either Red wire, repair open in Red wire between battery positive terminal and starter motor relay. See WIRING DIAGRAMS .
  5. Measure voltage between starter motor relay terminal (Red/Light Blue wire) and ground with ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, check starter motor relay mounting bolts and surfaces for looseness or corrosion. Repair as necessary. If relay is tight and mounting surface is free of corrosion, replace starter relay and check system operation.
  6. Disconnect Digital Transmission Range (DTR) sensor connector. Measure voltage between DTR sensor connector terminal No. 12 (Tan/Red wire) and ground with ignition switch in START position. See Fig 2. If battery voltage is present, go to next step. If battery voltage is not present, go to step  9.
    Fig 2: Identifying Digital Transmission Range (DTR) Sensor Terminals
    G98I07053Courtesy of FORD MOTOR CO.
  7. Measure resistance of Red/Light Blue wire between DTR sensor connector terminal No. 10 and starter motor relay. See Fig 2. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open in Red/Light Blue wire and check system operation.
  8. Check connections for looseness or corrosion. If connections are okay, adjust DTR sensor, reconnect all connectors and check system operation. See DIGITAL TRANSMISSION RANGE SENSOR  under ADJUSTMENTS. If starter still does not crank, replace DTR sensor and check system operation.
  9. Reconnect DTR sensor connector. Remove and inspect central junction box fuse No. 34 (10-amp). If fuse is okay, go to step  11. If fuse is blown, install new fuse and check system operation. If fuse blows again, check for short to ground between fuse No. 34 cavity (output side) and starter motor relay. Disconnect Red/Light Blue wire from starter motor relay and check resistance between fuse No. 34 cavity (output side) and ground. If resistance is greater than 10,000 ohms, replace shorted starter motor relay. If resistance is still less than 10,000 ohms, go to next step.
  10. Disconnect DTR sensor connector and check resistance between fuse No. 34 cavity (output side) and ground. If resistance is less than 10,000 ohms, repair short in Tan/Red wire. See WIRING DIAGRAMS . If resistance is greater than 10,000 ohms, measure resistance between DTR sensor connector terminal No. 10 and ground. See Fig 2. If resistance is less than 10,000 ohms, repair short to ground in Red/Light Blue wire. See WIRING DIAGRAMS . If resistance is greater than 10,000 ohms, install new DTR sensor and check system operation.
  11. Measure voltage between fuse No. 34 cavity (input side) and ground with ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, repair or replace central junction box or open Tan/Red wire between central junction box and DTR sensor connector.
  12. Disconnect ignition switch harness connector. Measure voltage between each ignition switch connector terminal BATT (Yellow wires) and ground. See Fig 3. If battery voltage is not present, go to step  14. If battery voltage is present, go to next step.
  13. Measure resistance of ignition switch between terminals BATT (either one) and ST with ignition switch in START position. If resistance is greater than 5 ohms, replace ignition switch and check system operation. If resistance is 5 ohms or less, check connectors for looseness or corrosion. If connections are okay, check for open in White/Pink wire between ignition switch connector and central junction box. If wire is okay, repair or replace central junction box.
    Fig 3: Identifying Ignition Switch Terminals
    G96D29358Courtesy of FORD MOTOR CO.
  14. Reconnect ignition switch connector. Remove and inspect battery junction box fuse No. 23 (60-amp). If fuse is okay, go to step  16. If fuse is blown, replace fuse and check system operation. If fuse blows again, short to ground is present between battery junction box fuse No. 23 and central junction box fuse No. 34 (resistance to ground is less than 10,000 ohms). Disconnect ignition switch connector and recheck resistance. If resistance is greater than 10,000 ohms, go to next step. If resistance is still less than 10,000 ohms, repair short to ground in appropriate Yellow wire. For power distribution wiring diagrams, see POWER DISTRIBUTION in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
  15. Measure resistance of ignition switch between each BATT terminal and ground in every switch position. See Fig 3. If resistance is less than 10,000 ohms in any switch position, replace ignition switch and check system operation. If resistance is greater than 10,000 ohms, repair short to ground in White/Pink wire between ignition switch and central junction box.
  16. Repair open in power distribution circuit. See POWER DISTRIBUTION in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Check system operation.
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