Hi,
I have an 03 5.4L F150 4x4.
90% of the time, no issues starting.
Once in a while, when I click the ignition, usually when it has sat still for more than an hour or so, it will give a loud grinding noise. The engine does not turn over, but there is that loud noise.
Checked cables, all grounds are fine, battery is charged real well.
Can wait two seconds, hit the switch again, and vroom it starts up and is ready to go.
Only once has it ever done the grinding noise on two subsequent key turns.
Usually happens once a week.
Drive the truck quite a bit, starting it at least 4 times a day.
Doesn't matter if it is 95deg and sitting in the sun all day, or if it has been 5deg and sitting in the cold all day.
Happens in cold, wet, dry, warm.

Any clues?
Took it to Ford, and they said there was nothing wrong since they couldn't do it in over 40 tries. Still got charged $100 for the time.
So I'm out $100 and nothing fixed.
And they are clueless on what is the problem.

I had heard about a similar issue a few years ago on this or another F150 sight, and the word then was that it was just due to weak starters in those years, and that I should have bought an aftermarket then, never did, maybe I should have.

Any ideas?

Thanks, first time member, first time post on this sight in eons.

 

mine does the same thing every once in a while. sometimes it will start right up if i try again. other times i have to pop start it. i try to park on a hill whenever i can for just this reason. anyway, it's most likely the starter. i've got a new one in the mail, should be coming in a few days. i'm going to put it in when i pull the trans to put the new clutch in, so hopefully that will fix it...especially with winter coming up, it always seems that starting problems like the rear their ugly head when it's winter time.

 

By your description of [loud grinding noise] it sounds like the starter is not engaging the flywheel completly. Wait and see if you get another reply from Steve or Bluegrass, but that is what it sounds like to me.

I don't know if you can clean this to get it to work again, or if it is a case of new starter time. I have always just replaced the complete starter when something like this happens. Early 70's Novas with header were very prone to this same problem, the headers cooked the starter, which was not designed to take that kind of abuse.

 

sounds like starter to me, take it out and look at the teeth. if your lucky your flywheel is ok.more grinding the worse ,a new starter might not line up with the flywheel teeth.i had chevy s 10 same problem . what a pain in the ***

 

This is a known issue. I'm a mechanic with many years of experience, and have replaced many a F150 starter that had this same symptom.
Most dealers won't replace something that they can't see fail themself.
Had one in and it never did it, so my service manager told me he couldn't replace it since it wasn't failing.
Had another one in, started it 30 times, nothing, 31st time it did it, so we replaced the starter.
Then, we had the truck from the previous week towed in because it wouldn't start at all. Now, if the customer has this "grinding" noise complaint, then we automatically replace them under warranty now.
Most garages won't do this though, until they see one for themselves fail.
And most don't fail, except once every few weeks or months.
I would suggest replacing it yourself, especially since you've had it do it so many times, and once more than once.
Or pay your local garage to replace one.
And yes, have them check your flywheel, almost always they are OK, but have seen them messed up slightly by this issue

 

Well, the starter is still doing its thing. crunching.....
Lance Cunningham Ford in Knoxville TN has never heard of such an issue.
Figures.
If anyone can refer me to a dealership that has had this problem in the past and now resolves them, let me know, maybe if I can get someone from within Ford to tell them that it is an issue and that they should replace them, then maybe I'll get some satisfaction from Lance Cunningham Ford.

Also, since I doubt they will do anything about it, can anyone suggest a good starter?
I had heard of lighter more powerful ones.


Thanks

 

lots of companys make high torque starters. those are for cranking over high comperssion big blocks etc.. more than enough for what u need.

 

Thanks. I do remember a couple of years ago people recommending some high performance lighter starters on this board. Looking for part numbers or model name/number so I can look them up online.

 

Ah, but our shop knows the issues, so we take care of our customers. Too bad you don't live near here.
Its too hard to get one Ford to tell another Ford about something like this. Unless it comes from corporate, they keep to their own. So, good luck in getting any dealership to help, unless they do the work for you.

 

Gentlemen, gentlemen, has no one heard of a starter drive? The starter drive is at the back of the starter and contains the gear that drives the flywheel.( the gear itself isn't what goes bad, and don't ask I can't explain exactly what does) This can be easily replaced by removing and disassemblng the starter. Doesn't take long to replace the drive if you know how to do it. You need to be careful not to pull the armature out of the brushes( at least on the older Ford starters) as this can be a REAL PAIN to get back together. If my current starter was working good except for the drive, I would replace just the drive, as some of the rebuilt starters are not that great.

 

yea the plunger gear that drives the flywheel. all kinds of springs etc.. in there. i agree some of the remans are not so good.they only replace the parts the absolutely have to. if he has the original starter just makes sense to replace the whole thing. how long before solenoid goes?