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Intermittent no crank - mechanics are no help - 02 XLT 4.6

pfunk027

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November 22, 2008
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Los Angeles
This problem has been going on for the better part of more than a year...

The problem: Engine will intermittently not crank. I'll turn the key and hear a click and the hum of what I assume to be the fuel pump, but it's as if the starter isn't getting any juice. 5 minutes later, or a day later, or an hour later (it's completely random), the engine will magically crank after absolutely no intervention.

I have handed the vehicle over to a mechanic (including a Ford dealership this past weekend) three times in this condition. The problem is that once a tech gets to the car, it starts right up and they can't troubleshoot my problem. This is so frustrating.

What I have tried:

The first time it happened, I changed the ignition relay. Granted, the car was cranking at the time I changed the relay, so I was just making a guess. The car worked fine for many months without any issues. Then, it started happening again. I then tried ANOTHER relay, but that wasn't the case.

It was suggested by a mechanic that couldn't troubleshoot the issue to try changing the ignition switch. So, I did that myself. That was on Thanksgiving day of last year. I immediately had it in the no crank condition later that day, but then it had no issues from then until last weekend.

It normally will not crank only once in a day and happen about once a week when it is doing it often. But on Saturday, it happened two consecutive times. So, I towed it to the dealership. I was curious, so as soon as it was off the truck, I tried to start it. Sure enough it did. I'm not sure if the vibration of the tow did it or what.They kept it for 2 days and could not duplicate the problem. I just picked the vehicle up because I can't guarantee it will happen to them anytime soon.

An interesting note - one time it happened at a service station. There was a mechanic on duty that took a quick look at it. He actually got me started by shorting the constant lead to the switched lead on the starter while I was turning the key. Does this mean that the problem is in the circuit before the starter?

I live in LA, so I'm going to assume temperature isn't a factor here. It has happened more frequently when it is warmer outside, but it has also happened on first crank in the morning.

Can anyone out there help? It would seem I am the only one that is going to be able to fix this (if I am even capable). What else in the circuit can fail intermittently and then magically fix itself? Is there a safety switch linked to the transmission? Can the security system intermittently fail like that? Can it be the starter? What should I do to try to troubleshoot the next time I am in the no crank situation?

Any help is greatly appreciated!
 






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