I completed an engine "rebuild" about 6 months ago. I put in a new fuel pump, new alternator, new starter, and a new starter solenoid. It DID start, but the smoke was pouring out like crazy. I finally accepted the fact that NOT having the heads resurfaced was a poor choice, even though the yard "guaranteed" me the compression was good. I pulled the heads, had them resurfaced, and this time I pulled apart the new 4 layer gasket and sprayed it with copper gasket spray before torquing it down with new bolts. When I went to start it, I put the key in, turned until the lights came on and I could hear the fuel pump kick in. When I went to engage the starter, it was just "click". I wasn't surprised ... figured the battery. I yanked the battery out and grabbed the good battery out of my running 2001 Expedition. I cleaned the contacts and posts, went to try it again, and NOTHING. By nothing, I mean: turn the key and no lights, no fuel pump, nothing. It made me think something wasn't happy with that bit of extra juice from the good battery. I've checked fuses and they all look good.

Any recommendations?

-Steve
Titusville, FL

 

Just to weed out the simple stuff....sorry I gotta ask....Is it in park?
Have you popped out the rubber plug on the bell housing and see if you can turn it over with a long screw driver? or tried pulled the spark plugs and see it it turns over then?

the solenoid on the fire wall good? battery cables good?

 

Yeah ... in park and I can turn the crankshaft.

I found this rather robust diagnostic guide in the service manual I'm gonna go through in the morning. I figure if this doesn't track it down, nothing will:

 

well ... that was easy. Continuity check between positive terminal on the battery and the starter solenoid shows no connection. So, time to replace my 19 year old battery cables.

 

I just thought I would share ... This was my first experience with a bad battery cable. I've disconnected the cables from the starter, starter solenoid, ground, and taken them out.

I can hook this thing up to the meter, wiggle it around, and watch the meter go from no connection to anything between 100 and 200 ohms (I've heard 4 ohms was acceptable), running around like crazy as I move and twist the cable. Its the damnedest thing. I never would have believed it if I hadn't witnessed it myself.

 

The stranded copper wire inside is probably corroded from moisture getting into the end joints.