Cables, Alternator, Regulator, Starter
Don't know if you've solved it yet but, here are some of my findings on my 228K 1991: I agree with Blee1099: several years back I had this same problem, the cables looked fine but inside were corroded, the starter cable was corroded end to end, INTERNALLY! The battery was brand new, CCA 875 amps. I installed new cables and it started like a new engine was installed. However, that was not the only problem. The alternator regulator was not functioning correctly all the time. The dash gauge needle would randomly go into discharge mode way down then up again. Installed a reman alternator and gauge problem went away. (I took it apart and the seals on the regulator were borken allowing corrosion.) Several weeks later the starter was sluggish when starting and finally wouldn't crank at all. It was the magnet solenoid on the starter, they corrode out. When I bought my reman starter there was a service bulletin included explaining the problem and Ford's resolution. The auto parts guy told me "They now replace the 1st Generation solenoid with the 2nd generation solenoid on all reman units." "It utilizes the M6X1.0 Threaded S terminal post and necessary connector.(info from FORD TSB #94-26-3)" If you have an earlier 1994 unit you may have this type starter. Also do you hear the click of the solenoid when you turn the key? If not it maybe the starter relay on the fender (1991 location). Since then the other mod I made was to install a smaller alternator pulley, it allows more output at lower rpm and here in NY in the winter time running heaters, defrosters, wipers in traffic, you need all the power you can get!
