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

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, 2002 Ford Excursion, and 2002 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove fuse No. 20 (15-amp) from central junction box. Check continuity of fuse No. 20 (15-amp). If fuse No. 20 is okay, reinstall fuse and go to next step. If fuse No. 20 is open, install NEW fuse and go to step  14.
  2. Measure voltage between ground and input side of central junction box fuse No. 20 while holding ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, go to step  4.
  3. Turn ignition switch to LOCK position. Disconnect ignition switch 15-pin connector. Measure resistance between in Red/Light Blue wire between input side of central junction box fuse No. 20 and ignition switch connector terminal STA. See Fig 1. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair poor connection or open in Red/Light Blue wire between ignition switch connector and central junction box. See WIRING DIAGRAMS . Check system operation.
    Fig 1: Identifying Ignition Switch Connector Terminals
    G98G01757Courtesy of FORD MOTOR CO.
  4. Turn ignition switch to LOCK position. Disconnect starter motor relay connector (Tan/Red wire on A/T; Dark Blue/Orange wire on M/T). Measure voltage between starter motor relay connector terminal (Tan/Red wire on A/T; Dark Blue/Orange wire on M/T) and ground while turning ignition switch to START position. If battery voltage is not present, go to next step (A/T) or go to step  10 (M/T). If battery voltage is present, replace starter motor relay. Check system operation.
  5. Disconnect Digital Transmission Range (DTR) sensor 12-pin connector. Measure resistance in Tan/Red wire between DTR sensor connector terminal No. 12 and starter motor relay connector terminal. See Figure. If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open in Tan/Red wire between DTR sensor and starter motor relay. See WIRING DIAGRAMS . Check system operation.
  6. Perform DTR sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR  under ADJUSTMENTS. If DTR sensor is adjusted properly, go to next step. If DTR requires adjustment, adjust as necessary. Check system operation.
  7. Restore all connections except DTR sensor. Connect a jumper wire between DTR sensor connector terminals No. 12 (Tan/Red wire) and No. 10 (White/Pink wire or Dark Blue/Orange wire). See Figure. Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace DTR sensor. See DIGITAL TRANSMISSION RANGE SENSOR (DTR)  under REMOVAL & INSTALLATION. Check system operation.
  8. Disconnect Clutch Pedal Position (CPP) jumper 6-pin connector. Measure resistance between DTR connector terminal No. 10 (White/Pink wire or Dark Blue/Orange wire) and CPP jumper connector terminal No. 2 (Dark Blue/Orange wire). See Figure and Fig 2 . If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair wiring between DTR sensor and CPP switch jumper. See WIRING DIAGRAMS . Check system operation.
    Fig 2: Identifying Clutch Pedal Position Switch Or Jumper Connector Terminals
    G98A01759Courtesy of FORD MOTOR CO.
  9. Measure resistance between CPP jumper terminals No. 1 and No. 2 (component side). If resistance is less than 5 ohms, go to step  12. If resistance is greater than 5 ohms, replace CPP jumper. Check system operation.
  10. Disconnect starter motor relay connector. Disconnect CPP switch 6-pin connector. Measure resistance in Dark Blue/Orange wire between starter motor relay connector terminal and CPP switch connector terminal No. 2. See Fig 2. If resistance is less than 5 ohms, reconnect starter motor relay and go to next step. If resistance is greater than 5 ohms, repair open in Dark Blue/Orange wire between CPP switch and starter motor relay. See WIRING DIAGRAMS . Check system operation.
  11. Connect jumper wire between CPP switch connector terminals No. 1 (White/Pink wire) and No. 2 (Dark Blue/Orange wire). Connect an additional jumper wire between CPP switch connector terminals No. 5 (White/Pink wire) and No. 6 (Gray/Yellow wire). See Fig 2. Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace CPP switch. See CLUTCH PEDAL POSITION (CPP) SWITCH  under REMOVAL & INSTALLATION. Check system operation.
  12. Disconnect central junction box Black 34-pin connector. Measure resistance of White/Pink wire between central junction box connector terminal No. 4 and CPP switch/jumper connector terminal No. 1. If resistance is less than 5 ohms, replace central junction box. If resistance is greater than 5 ohms, repair open in White/Pink wire between central junction box and CPP switch/jumper. Check system operation.
  13. Remove fuse No. 20 (15-amp) from central junction box. Measure resistance between ignition switch connector terminal STA (Red/Light Blue wire) and ground. See Fig 1. If resistance is greater than 10 k/ohms, replace ignition switch. Check system operation. If resistance is less than 10 k/ohms, repair short to ground on Red/Light Blue wire between ignition switch and central junction box. See WIRING DIAGRAMS .
  14. Turn ignition switch to START position. Turn ignition switch to LOCK position. Check fuse No. 20 (15-amp) in central junction box. If fuse is open, install NEW fuse and go to next step. If fuse is okay, system is okay at this time.
  15. Disconnect starter motor relay connectors. Turn ignition switch to START position. Turn ignition switch to LOCK position. Recheck fuse No. 20. If fuse is open, install NEW fuse and go to next step. If fuse is okay, replace starter motor relay. See STARTER MOTOR RELAY  under REMOVAL & INSTALLATION. Check system operation.
  16. Disconnect CPP switch or CPP jumper connector. Measure resistance between CPP switch or CPP jumper connector terminal No. 1 (White/Pink wire) and ground. See Fig 2. If resistance is greater than 10 k/ohms, go to next step (A/T) or go to step  19 (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.
  17. Disconnect DTR sensor connector. Measure resistance between DTR sensor connector terminal No. 10 (Dark Blue/Orange wire) and ground. See Figure. If resistance is greater than 10 k/ohms, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Dark Blue/Orange wire between DTR sensor and CPP jumper. See WIRING DIAGRAMS . Check system operation.
  18. Measure resistance between DTR sensor connector terminal No. 12 (Tan/Red wire) and ground. If resistance is greater than 10 k/ohms, replace DTR sensor. See DIGITAL TRANSMISSION RANGE SENSOR (DTR) under REMOVAL & INSTALLATION. Check system operation. If resistance is less than 10 k/ohms, repair short to ground in Tan/Red wire between DTR sensor and starter motor relay. See WIRING DIAGRAMS . Check system operation.
  19. Disconnect starter motor relay connectors. Measure resistance between CPP switch connector terminal No. 2 (Dark Blue/Orange wire) and ground. If resistance is greater than 10 k/ohms, replace CPP switch. See CLUTCH PEDAL POSITION (CPP) SWITCH  under REMOVAL & INSTALLATION. Check system operation. If resistance is less than 10 k/ohms, repair short to ground on Dark Blue/Orange wire between CPP switch and starter motor relay. See WIRING DIAGRAMS . Check system operation.
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