Yesterday my '05 5.4L developed an intermittent "click" and no crank problem. After trying to start 6 or 7 times, it finally cranked and started. This morning the "click" no crank problem was back. In doing some voltage measurements while my wife turned the key to the start position, I found that both solenoid terminals had 12V. I then measured the wire going into the starter and it only had 300mV. I then disconnected the negative battery terminal, and removed the wire connector from the starter solenoid going into the starter. The solenoid terminal nut was not tight, and I could see arcing burns on the bottom side of the connector. I then cleaned the cable terminal, and the solenoid terminal with a wire brush, and tighten the nut. Problem fixed, no parts needed.

 

Nice find that you were able to fix yourself. I will have to remember this if I ever have such an issue.

 

Thanks!

 

Glad ya found it.....interesting that it was loose though....

 

Thanks! Yes, only the starter side terminal was loose. The battery side was tight, and the coil terminal were tight.