00 Limited v8 wont crank intermittently

[smcmoran]

Good evening all. I'm almost stumped and could used a fresh set of eyes(or brains) on my issue. Its a 00 Explorer limited, 5.0 AWD, 182kmi. runs great when it cranks. This has happened a couple times and its always at the worst possible time. You try to start it and there is nothing but a relay click. The lights do not dim, but the radio and other accessories turn off as they should. So far I have changed the battery, starter, battery terminal, neutral safety(range switch) and each time the truck started cranking again. The first couple times it was the battery connections, and they looked a little corroded. The last one was the neutral safety which was very stiff and its lasted about 4 months. Today my wife ran an errand and came home, the truck we up to temp and then sat for about 2 hours. She then went to go to work and nothing. Got lights and radio, showing 12.4v on the battery but nothing.

I tried jumping it with a hot box, different keys, arming and disarming the alarm, unlocked with the door code, and nothing. When I replaced the neutral safety, I thought that was my last idea. Now I am wondering about the battery cables themselves. I find it hard to believe that corrosion in the cable would drop the voltage enough. Also it seems too abrupt. Almost like the voltage has hit a threshold and now won't engage the starter.

Let me know if anyone has any ideas as I am at the end of my proverbial rope. Next steps are going to be replacing the battery terminals again, with some high end units I purchased a while ago and probably replacing the Battery cables(looks like fun) What I hate is the unknown, I really want to know what is causing it to NOT turn over.

Thanks in advance!!!

Scott

 

[koda2000]

have you tried switching out the starter relay in the power distribution box? have you examined your battery cables closely for lumps and/or signs of corrosion?

 

[smcmoran]

didn't know there's was a relay in the distribution block have to look for it. as far as the cables they show just a little bit of corrosion inside underneath the jacket but no lumps or bubbles. I'll
get to work researching the distribution block. any other ideas?

 

[jremington59]

That can be enough. Have someone turn the key over while you grab the cable and move it around. When you replaced the terminals did you cut them back a little until the wire was clean?

didn't know there's was a relay in the distribution block have to look for it. as far as the cables they show just a little bit of corrosion inside underneath the jacket but no lumps or bubbles. I'll
get to work researching the distribution block. any other ideas?

 

[Turdle]

Intermittent connection in the starter braided cable. Next time it will not start, move that braided cable around a bit and try again.--

 

[koda2000]

Intermittent connection in the starter braided cable. Next time it will not start, move that braided cable around a bit and try again.--

the OP stated he has already changed the starter.

 

[Turdle]

the OP stated he has already changed the starter.

Ooops. Missed that I guess.

 

[stroker331]

sounds like the relay to me...

 

[smcmoran]

I just swapped the relay....nothing. I re-terminated the cable ends, cutting back and wire brushing the wires, nothing. For the heck of it I tried arming and disarming the alarm again, nothing. In the all data manual it listed a solenoid relay but I don't see one anywhere.

I can hear the relays clicking but nothing from the starter. I haven't climbed under yet since its in front of the house parked on the snow.

In the past I would take apart the terminals and clean them and it would start cranking again but they are so clean now that can't be it.

Couple thoughts - it is very low on fuel, wife like to run it to empty, there wouldn't be a sensor that would keep the starter from turning if the fuel was low, would there be? The other thing I keep coming back to is the anti-theft. Is there something in that preventing it from turning over? Don't have the manual so I'm not sure what it does.

I appreciate all the help, keep it coming

 

[smcmoran]

Just put gas in the tank, nothing. checked it with OBDII scanner, nothing. so then I had my wife hold the key in the start position and started shaking cables, was doing nothing and then just after I stopped, it started cranking. It cranked for about 5 sec and then she let the key off. Was so excited we tried it again and ...you guessed it, nothing. I tried everything and couldn't reproduce it. I hate intermittents.

Calling it quits for the night. Tomorrow the storm hits and my wife is supposed to work the night shift in the ED. So I got one more shot to get her going. I prices out the pos battery cable from fordparts and its 150.00. Unless I can come up with a great idea, I'm sending it to the dealer tomorrow morning. Let them come up with something.

 

[jremington59]

When you changed the starter did you get everything back on tight? Down by the starter there is an angle in the cable that apparently causes a lot of problems according to a mechanic friend. I'd get under it and wiggle the cable while your wife holds the key on and see if it cranks. Just keep your hands away from moving parts, lol.