2006 XLT Takes longer and longer to start when cold

[Scorpion8]

My 2006 XLT runs great, except .... it turns over longer and longer lately when starting cold. Used to fire right up on key turn-on. Now it cycles for a few moments but it seems to be getting longer. It always starts. My last plug change was circa 2014, but the coil packs have been renewed (Motorcraft) a few (~2) years ago. We have no Ford dealer, but we have an ex-Ford dealer who still works on them. I'd prefer OEM parts, but surely the years, age and environment in Alaska means this vehicle (~180,000) may be coming to an end, so offshore parts may be just fine for now. Question: the broken plug tool is about $80, but how hard is it to remove a broken plug myself? The ex-dealer did the plugs when I last had them done, so I hope he did the right thread anti-seize. Fuel filter too? What else could it be?

He wants $1600 to do the work. Parts (using generic coil packs) are about $350 if I can do it myself.

Expert opinions?

 

[94Eddie]

Try cycling the ignition on and off 2-3 times without starting the engine. Hold the key in the "on" position around two seconds for each cycle. Then try to start the engine. If it then starts normally, you might have a clogged fuel filter and/or a fuel pump going bad. Spark should be good if you replaced the coils with OEM parts. I don't think it is an air intake issue. Does it run smoothly once it starts? Also, is it a V6 or V8 model?

 

[Scorpion8]

Yes, it's a good strong engine still. Misfires a bit under light acceleration (plus or coils) but always has since I've owned it. I'll try that test tomorrow, what am I looking for in response?

 

[94Eddie]

When a filter is clogged, or the fuel pump is weak and failing, the fuel pressure does not ramp up enough on the first turn of the ignition to start the engine normally. Cycling the pump a few times before turning the engine over can get the fuel pressure built up to the psi level the engine needs to start reliably and quickly. This is a way to determine if a starting issue is resulting from low fuel pressure. Do you have a V6 or V8 engine?

 

[Scorpion8]

4.6L V-8. I have a new fuel filter, but frankly it's lost somewhere. They're cheap enough, just gotta wait for better weather to crawl under the car.

 

[Scorpion8]

Did not seem to make a difference perceptibly. Turned key 2 or 3x at two different cold starts.

 

[Blackhawkxx]

One simple thing to check is the battery. One that isn't putting out enough CCA and volts can lengthen the start time. Most auto parts stores will test your battery in the vehicle for free.

 

[FordFlintrock]

My 2006 XLT runs great, except .... it turns over longer and longer lately when starting cold. Used to fire right up on key turn-on. Now it cycles for a few moments but it seems to be getting longer. It always starts. My last plug change was circa 2014, but the coil packs have been renewed (Motorcraft) a few (~2) years ago. We have no Ford dealer, but we have an ex-Ford dealer who still works on them. I'd prefer OEM parts, but surely the years, age and environment in Alaska means this vehicle (~180,000) may be coming to an end, so offshore parts may be just fine for now. Question: the broken plug tool is about $80, but how hard is it to remove a broken plug myself? The ex-dealer did the plugs when I last had them done, so I hope he did the right thread anti-seize. Fuel filter too? What else could it be?
He wants $1600 to do the work. Parts (using generic coil packs) are about $350 if I can do it myself.
Expert opinions?

The 5.4 engine was the one known for breaking plugs. After checking battery and if still using original starter they can crank over more slowly which will extend start time before dying altogether. At your mileage timing chains and tensioners might be in the equation.

Yes, it's a good strong engine still. Misfires a bit under light acceleration (plus or coils) but always has since I've owned it. I'll try that test tomorrow, what am I looking for in response?

Plugs and coil overs have been changed so your "misfire" is likely not ignition related if the job done correctly. Remove and plug the vacuum hose to EGR and road test for the light acceleration surge. Remove one spark plug checking gap and condition. A cylinder power balance test should be performed.

 

[BrownsFan42]

2007 Eddie Bauer Explorer, 4.0, 4x4, 219K miles.

I'd look at the starter. Mine was the original starter.

I had the same starting problem. Normally, it started right up, but in the past 6 months it took longer to start. I replaced the spark plugs and fuel filter, but the "long crank" start problem continued.

Then the starter crapped out entirely in late January, 2025. Towed it to the mechanic...replaced the starter. All problems solved. Starts right up...even in sub-zero weather. I love this car!

 

[Scorpion8]

Thanks, another thing to check out.