So this is my first Ford and it left me stranded at work today. I came back from lunch and parked the truck. When I came out after work to leave, it wouldn't turn over. The battery power seemed OK but all I get is a big click when the key is turned to the Start position. It sounds like the starter solenoid is making the noise, so I assumed the starter was bad. Changed the starter in the parking lot at work and still have the same problem!

I tried to jump start it just to make sure...didn't help at all. I also tried the starter with the head lights on...they dim a little but they don't go out. I'm really disappointed that the starter wasn't the problem. I'm thinking that maybe the heavy wire from the battery to the starter terminal lug is bad somehow?? I didn't have my test meter with me.

Has anybody had an issue like this before?? Thanks

 

I know this is going to sound crazy, but have you crawled underneath there and banged on the starter a few good times with a hammer? I've done that with both of my Fords in the past and had success. The pinion gets stuck sometimes... I know you got a new one... but it doesn't cost you anything to try. Good luck!

 

Sounds like a corroded wire, just inside the ring terminal, to the starter or at the battery ( or both ).

Some what common, it might show OK with a meter, the only way to check it is to pull the ring terminal, and bend the wire to see if it breaks off.

The reason it might test fine with the meter is only a few strands in the wire are not corroded through, where a high AMP draw shows the problem ???

All of this is a SWAG, until you can remove the cable and check it.

 

I replaced my '97 starter cable after only a few years, it corroded off near the starter. Personally would replace with marine cable (tinned wire) for better corrosion protection and sometimes find it cheaper than a direct replacement OEM.

Don't bang on the starter motor frame, on the solenoid is ok. The motor frame has magnets inside and can break. I see them come thru warranty all the time and we reject them back to the dealer.

 

Thanks for all the tips. Over the weekend I got my test meter and began to check all the wires. After several other tests, I connected the meter to the input on the starter relay (from the ignition switch) to make sure the relay was getting power from the switch. When I turned the ignition key to "start"......it started! This really wasn't good news because I didn't get to find the problem for sure. I was not able to duplicate the problem again.

I did notice though that while I was poking around with the test leads, the ground wire from the starter to the frame was rusted pretty badly at the frame. I removed all of the wiring from battery to starter relay to starter solenoid and to ground....cleaned all terminals and lugs and lubed/assebled everything. I'm hoping it was a corroded connection somewhere that I have since fixed. There was a lot of rust on several connections.

Looking back now, I think the "clicking" I heard and assumed was the starter solenoid was actually the starter relay. I don't think I was getting power to the starter after all...probably because of the rusted ground connection.

Thanks again for the help and I'll keep this thread updated if anything should change. But for now....problem is fixed!