Contents Section: Starter All sections

Starting System - Diesel Models -- E-Series Ford Cutaway E350 Super Duty

Starter 27 illustrations ~3629 words

GENERAL SPECIFICATIONS

ItemSpecification
Normal engine cranking speed185 rpm
Starter motor no load current draw155 amps max.
Starter motor normal load current draw365 amps
Starter motor maximum load current draw1,300 amps
Starter motor minimum stall torque @ 2.5 volts74 Nm (55 lb-ft)
Starting circuit maximum voltage drop (engine at normal operating temperature)0.5 volt

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNmLb-ftLb-in
Harness bracket nut2518
Solenoid B-terminal nuts12106
Solenoid wire nut653
Starter mounting bolts (1)
(1) Refer to the appropriate procedure(s).
(1)Refer to the appropriate procedure(s).

TORQUE SPECIFICATIONS

The starting system consists of the following

  1. Starter motor
  2. Starter solenoid
  3. Starter motor relay
  4. Starter drive
  5. Battery
  6. Ignition switch
  7. PCM

The function of the starting system is to crank the engine at a speed fast enough to permit the engine to start. When the starter solenoid is energized, a magnetic field is created in the starter solenoid windings. The iron plunger core is drawn into the starter solenoid coil, and a drive lever and pin connected to the starter drive engages the drive pinion gear to the flexplate/flywheel ring gear. When the plunger is pulled all the way in, the contact disc closes the circuit between the battery and the motor feed terminals. This sends current to the motor and the drive pinion gear cranks the flexplate/flywheel to start the engine. When current flows to the starter motor, the starter solenoid pull-in coil is bypassed, and the hold-in coil keeps the drive pinion gear engaged with the flexplate/flywheel.

The TorqShift transmission has a Park/Neutral Position (PNP) switch in the transmission. The PNP switch prevents operation of the starter motor unless PARK or NEUTRAL is selected.

Starting System - Anti-Theft Intervention

If equipped, the starting system is electronically controlled by the Passive Anti-Theft System (PATS). The PATS recognizes the correct electronically coded ignition key and signals the PCM to provide a ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby allowing the starter motor to activate.

Refer to appropriate System Wiring Diagrams article for schematic and connector information.

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Flex Probe Kit 105-R025D or equivalent Fluke 77-IV Digital Multimeter FLU77-4 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 29

Scheme 29: Special Tool(s)

Scheme 30

Scheme 30

Scheme 31

Scheme 31

Principles of Operation

The starting system is electronically controlled by the PCM. The PCM recognizes the signal from the ignition switch and provides a ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby allowing the starter motor to activate.

If equipped, the starting system is electronically controlled by the Passive Anti-Theft System (PATS). The PATS recognizes the correct electronically coded ignition key and signals the PCM to provide a ground for the starter relay. The energized relay provides voltage to the starter solenoid, thereby allowing the starter motor to activate.

Inspection and Verification

WARNINGBefore carrying out maintenance on the starting system, disconnect the battery ground cable from the frame to completely isolate the starter from the dual frame-mounted batteries. Failure to follow this instruction may result in serious personal injury.

Note. If equipped, PATS must be functioning correctly before a logical starting system diagnosis can be carried out. Address PATS concerns before continuing.

  1. Verify the customer concern by operating the starting system to duplicate the conditions.
  2. Remove the accessory drive belt. Refer to «ACCESSORY DRIVE»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessory-drive-belts/#accessory-drive-system-e-series) . Verify the crankshaft and each of the components driven by the accessory drive belt rotate and are not seized or damaged.
  3. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Flexplate Starter motor Starter motor bolts Passive Anti-Theft System (PATS) Battery Battery Junction Box (BJB) fuse 13 (30A) Smart Junction Box (SJB) fuse 27 (20A) Damaged wiring harness Loose or corroded connections Starter relay
  4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  5. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
  6. If the scan tool does not communicate with the VCM : check the VCM connection to the vehicle. check the scan tool connection to the VCM . refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) , No Power To The Scan Tool, to diagnose no power to the scan tool.
  7. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) to diagnose no response from the PCM.
  8. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) . If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
  9. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
  10. If the DTCs retrieved are related to the concern, go to the «PCM DTC CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) . For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#multifunction-electronic-modules-e-series) .
  11. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series__symptom-chart) .

DTC Charts

DTCDescriptionAction
P0705TR Sensor Circuit FailureRefer to the appropriate Automatic Transmission article for the procedure.
P1702TR Sensor Circuit FailureRefer to the appropriate Automatic Transmission article for the procedure.
P1705TR Sensor Circuit FailureRefer to the appropriate Automatic Transmission article for the procedure.

PCM DTC CHART

Symptom Chart

ConditionPossible SourcesAction
The engine does not crank/the relay does/does not clickPassive Anti-Theft System (PATS) Battery Circuitry Ignition switch PCM Starter motor Starter motor relay Digital Transmission Range (TR) sensorGO to PINPOINT TEST A .
The engine cranks slowlyBattery Circuitry Starter motorGO to PINPOINT TEST B .
Unusual starter noiseIncorrect starter drive engagement Starter motor mounting Starter motorGO to PINPOINT TEST C .
The starter spins but the engine does not crankStarter motorINSPECT the starter motor mounting and engagement. REPAIR as necessary.
Damaged flexplate ring gear teethINSPECT the flexplate ring gear for damaged, missing or worn teeth. REPAIR as necessary.

SYMPTOM CHART

Pinpoint Test A: The Engine Does Not Crank/The Relay Does/Does Not Click

Refer to appropriate System Wiring Diagrams article for schematic and connector information.

Normal Operation

In normal operation, voltage from Smart Junction Box (SJB) fuse 27 (20A) is supplied to the ignition switch through circuit SBP27 (BU/RD). When the ignition switch is placed in the START position, voltage is supplied through circuit CDC35 (BU/WH) to the starter relay. The starter relay is supplied ground from the PCM through circuit CDC12 (YE). Power is supplied at all times to the starter motor from the battery through circuit SDC02 (RD). The starter relay has voltage supplied at all times from Battery Junction Box (BJB) fuse 13 (30A), through circuit SBB13 (GY/RD). When the starter relay is energized, voltage supplied to the starter relay is sent to the starter motor solenoid through circuit CDC25 (BN/GN). The starter motor is disengaged when the key is released from the START position.

This pinpoint test is intended to diagnose the following

  1. Passive Anti-Theft System (PATS)
  2. Battery
  3. Circuitry
  4. Ignition switch
  5. PCM
  6. Starter motor
  7. Starter motor relay
  8. Digital Transmission Range (TR) sensor

Scheme 32

Scheme 32: PINPOINT TEST A: THE ENGINE DOES NOT CRANK/THE RELAY DOES/DOES NOT CLICK

Scheme 33

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Scheme 35

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Scheme 44

Scheme 44
  1. A1 CHECK THE BATTERY Check the battery condition and charge. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) . Is the battery OK? Yes: GO to A2 . No: CHARGE or INSTALL a new battery as necessary. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
  2. A2 CHECK THE PCM FOR DTCs Check for PCM DTCs. Were any PCM DTCs retrieved? Yes: If PCM DTC P1260 is retrieved, REFER to «ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS)»(/ford/cutaway-e350-super-duty/2008-2012/remont/door-locks-anti-theft-systems/#anti-theft-system-passive-anti-theft-system-pats-e-series) . All other PCM DTCs, REFER to «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) . No: GO to A3 .
  3. A3 CHECK THE DIGITAL TR SENSOR PID Enter the following diagnostic mode on the scan tool: PCM DataLogger/PID. While observing the PCM TR sensor PID, place the vehicle in PARK and NEUTRAL. Does the PID match the gear selection? Yes: GO to A4 . No: GO to «AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT»(ref-370580) to diagnose the digital TR sensor.
  4. A4 CHECK THE BATTERY GROUND CABLE Measure the voltage between the positive battery post and the battery ground cable connection at the engine. Is the voltage greater than 10 volts? Yes: GO to A5 . No: INSTALL a new battery ground cable. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
  5. A5 CHECK THE STARTER MOTOR GROUND Measure the voltage between the positive battery post and the starter motor case. Is the voltage greater than 10 volts? Yes: GO to A6 . No: CLEAN the starter motor mounting flange and make sure the starter motor is correctly mounted. TEST the system for normal operation.
  6. A6 CHECK THE POWER SUPPLY TO THE STARTER MOTOR Measure the voltage between starter motor C197A-1, circuit SDC02 (RD) and ground. Is the voltage greater than 10 volts? Yes: GO to A7 . No: INSTALL a new positive battery cable. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) . TEST the system for normal operation.
  7. A7 CHECK THE STARTER MOTOR Connect one end of a fused jumper wire to starter motor solenoid C197A-1, circuit SDC02 (RD). Momentarily connect the other end of the jumper to starter motor solenoid C197B-1, circuit CDC25 (BN/GN). Did the starter motor engage and the engine crank? Yes: GO to A8 . No: INSTALL a new starter motor. REFER to «STARTER MOTOR»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) . TEST the system for normal operation.
  8. A8 CHECK FOR POWER TO THE STARTER MOTOR RELAY NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Starter Motor Relay. Measure the voltage between starter motor relay cavity 3, circuit SBB13 (GY/RD) and ground. Is the voltage greater than 10 volts? Yes: GO to A9 . No: REPAIR circuit SBB13 (GY/RD). TEST the system for normal operation.
  9. A9 CHECK FOR START REQUEST AT THE STARTER RELAY NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Starter Motor Relay. Key in START position. Measure the voltage between starter motor relay cavity 1, circuit CDC35 (BU/WH) and ground with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes: GO to A10 . No: GO to A12 .
  10. A10 CHECK THE RELAY GROUND CIRCUIT NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Disconnect: Starter Motor Relay. Key in START position. Measure the voltage between starter motor relay cavity 1, circuit CDC35 (BU/WH) and starter motor relay cavity 2, circuit CDC12 (YE) with the ignition switch in the START position. Is the voltage greater than 10 volts? Yes: GO to A17 . No: GO to A11 .
  11. A11 CHECK CIRCUIT CDC12 (YE) FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Starter Motor Relay. Disconnect: PCM C1381B. Measure the resistance between starter motor relay pin cavity 2, circuit CDC12 (YE) and PCM C1381B-4, circuit CDC12 (YE), harness side. Is the resistance less than 5 ohms? Yes: DIAGNOSE the PCM. REFER to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) . No: REPAIR circuit CDC12 (YE). TEST the system for normal operation.
  12. A12 CHECK THE IGNITION SWITCH Carry out the Ignition Switch Component Test. Refer to «COMPONENT TESTING -- E-SERIES»(/ford/cutaway-e350-super-duty/2008-2012/remont/accessories-control-systems/#component-testing) for component testing. Does the ignition switch test good? Yes: GO to A13 . No: INSTALL a new ignition switch. TEST the system for normal operation.
  13. A13 CHECK CIRCUIT CDC35 BETWEEN THE IGNITION SWITCH AND IN-LINE CONNECTOR C219 FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Ignition Switch C250. Disconnect: In-Line Connector C219. Measure the resistance between ignition switch C250-5 circuit CDC35 (BU/WH), harness side and in-line C219-35 circuit CDC35 (BU/WH), male side. Is the resistance less than 5 ohms? Yes: GO to A14 . No: REPAIR circuit CDC35 (BU/WH). TEST the system for normal operation.
  14. A14 CHECK CIRCUIT CDC35 AT IN-LINE CONNECTOR C219 FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: In-Line Connector C219. Measure the resistance between in-line C219-35 circuit CDC35 (BU/WH), female side and in-line C219-20 circuit CDC35 (BU/WH), female side. Is the resistance less than 5 ohms? Yes: GO to A15 . No: REPAIR circuit CDC35 (BU/WH). TEST the system for normal operation.
  15. A15 CHECK CIRCUIT CE336 FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Smart Junction Box (SJB) C2280B. Disconnect: In-Line Connector C219. Measure the resistance between in-line C219-20 circuit CE336 (GN/WH), male side and SJB C2280B-32 circuit CE336 (GN/WH). Is the resistance less than 5 ohms? Yes: GO to A16 . No: REPAIR circuit CE336 (GN/WH). TEST the system for normal operation.
  16. A16 CHECK CIRCUIT CDC35 (BU/WH) BETWEEN STARTER RELAY CAVITY 1 AND SJB CONNECTOR C2280E FOR AN OPEN NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Starter Motor Relay. Disconnect: Smart Junction Box (SJB) C2280E. Measure the resistance between starter relay cavity 1 circuit CDC35 (BU/WH) and SJB C2280E-8circuit CDC35 (BU/WH), harness side. Is the resistance less than 5 ohms? Yes: INSTALL a new SJB . TEST the system for normal operation. No: REPAIR circuit CDC35 (BU/WH). TEST the system for normal operation.
  17. A17 CHECK THE CIRCUIT TO THE STARTER MOTOR NOTE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. Ignition OFF. Disconnect: Starter Motor Solenoid C197B. Disconnect: Starter Motor Relay. Measure the resistance between starter motor C197B-1, circuit CDC25 (BN/GN) and starter motor relay cavity 5, circuit CDC25 (BN/GN). Is the resistance less than 5 ohms? Yes: INSTALL a new starter motor relay. TEST the system for normal operation. No: REPAIR circuit CDC25 (BN/GN). TEST the system for normal operation.

Pinpoint Test B: The Engine Cranks Slowly

Refer to appropriate System Wiring Diagrams article for schematic and connector information.

In normal operation, voltage from Smart Junction Box (SJB) fuse 27 (20A) is supplied to the ignition switch through circuit SBP27 (BU/RD). When the ignition switch is placed in the START position, voltage is supplied through circuit CDC35 (BU/WH) to the starter relay. The starter relay is supplied ground from the PCM through circuit CDC12 (YE). Power is supplied at all times to the starter motor from the battery through circuit SDC02 (RD). The starter relay has voltage supplied at all times from Battery Junction Box (BJB) fuse 13 (30A), through circuit SBB13 (GY/RD). When the starter relay is energized, voltage supplied to the starter relay is sent to the starter motor solenoid through circuit CDC25 (BN/GN). The starter motor is disengaged when the key is released from the START position.

This pinpoint test is intended to diagnose the following

  1. Battery
  2. Starter motor/solenoid
  3. Circuit

Note. Before beginning this test, be sure that the battery is tested and fully charged.

Scheme 45

Scheme 45: PINPOINT TEST B: THE ENGINE CRANKS SLOWLY
  1. B1 CHECK THE VOLTAGE TO THE STARTER Ignition OFF. Measure the voltage between the starter motor solenoid positive terminal and ground. Is the voltage 10 volts or greater? Yes: GO to B2 . No: REPAIR the circuit between the battery and the starter solenoid. CLEAN and TIGHTEN the connections at the battery terminals. TEST the system for normal operation.
  2. B2 CHECK THE MOTOR GROUND CIRCUIT Carry out the Motor Ground Circuit Voltage Drop Test. Refer to the «COMPONENT TESTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series__component-tests) . Is the ground OK? Yes: INSTALL a new starter motor. TEST the system for normal operation. No: REPAIR the ground circuit as necessary. TEST the system for normal operation.

Pinpoint Test C: Unusual Starter Noise

Refer to appropriate System Wiring Diagrams article for schematic and connector information.

In normal operation, voltage from Smart Junction Box (SJB) fuse 27 (20A) is supplied to the ignition switch through circuit SBP27 (BU/RD). When the ignition switch is placed in the START position, voltage is supplied through circuit CDC35 (BU/WH) to the starter relay. The starter relay is supplied ground from the PCM through circuit CDC12 (YE). Power is supplied at all times to the starter motor from the battery through circuit SDC02 (RD). The starter relay has voltage supplied at all times from Battery Junction Box (BJB) fuse 13 (30A), through circuit SBB13 (GY/RD). When the starter relay is energized, voltage supplied to the starter relay is sent to the starter motor solenoid through circuit CDC25 (BN/GN). The starter motor is disengaged when the key is released from the START position.

This pinpoint test is intended to diagnose the following

  1. Starter mounting
  2. Starter motor
  3. Incorrect starter drive engagement
  1. C1 CHECK THE STARTER MOTOR MOUNTING Inspect the starter motor mounting brackets for cracks. Check the starter motor mounting bolts for looseness. Is the starter motor mounted correctly? Yes: GO to C2 . No: REINSTALL the starter motor correctly.
  2. C2 INSPECT THE STARTER MOTOR Remove the starter motor. Inspect the starter motor for damage. Is the starter motor damaged? Yes: INSTALL a new starter motor. TEST the system for normal operation. No: CHECK the starter motor gear and the flexplate ring gear. REFER to «STARTER MOTOR DRIVE GEAR AND FLYWHEEL RING GEAR INSPECTION»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) . INSTALL new components as necessary. TEST the system for normal operation.

Component Tests

WARNINGBefore carrying out maintenance on the starting system, disconnect the battery ground cable from the frame to completely isolate the starter from the dual frame-mounted batteries. Failure to follow this instruction may result in serious personal injury.

Always make the Fluke 77-IV Digital Multimeter connections at the component terminal rather than at the wiring end connector. Making a connection at the wiring end connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component.

Scheme 46

Scheme 46: Starter Motor - Motor Feed Circuit

Scheme 47

Scheme 47
  1. Make sure the battery is fully charged; carry out a battery load test. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
  2. Disconnect the Inertia Fuel Shutoff (IFS) switch.
  3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
  4. Connect the Fluke 77-IV Digital Multimeter positive lead to the battery positive (+) post. Connect the negative lead to the starter solenoid M-terminal. PARTS DESCRIPTION CHART Item Part Number Description 1 - S-terminal 2 - Remote starter switch 3 10653 Battery 4 - Fluke 77-IV Digital Multimeter 5 - B-terminal 6 - M-terminal
  5. Engage the remote starter switch. Read and record the voltage. The steady voltage reading should be 0.5 volt or less.
  6. If the steady voltage reading is 0.5 volt or less, go to the starter motor-ground circuit «COMPONENT TEST»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series__component-tests) .
  7. If the steady voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid. Move the Fluke 77-IV Digital Multimeter negative lead to the starter solenoid B-terminal and repeat the test. If the steady voltage reading at the B-terminal is lower than 0.5 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts. PARTS DESCRIPTION CHART Item Part Number Description 1 - S-terminal 2 - Remote starter switch 3 10653 Battery 4 - Fluke 77-IV Digital Multimeter 5 - B-terminal 6 - M-terminal
  8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6 . If the steady voltage drop reading is still greater than 0.5 volt when checked at the M-terminal and less than 0.5 volt when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
  9. If the steady voltage reading taken at the solenoid B-terminal is still greater than 0.5 volt after cleaning the cables and connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself.
  10. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new positive battery cable.

Starter Motor - Ground Circuit

A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. Check the voltage drop in the ground circuit as follows

  1. Connect the Fluke 77-IV Digital Multimeter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal.
  2. Engage the remote starter switch and crank the engine. Read and record the steady voltage reading. The reading should be 0.5 volt or less.
  3. If the steady voltage drop is more than 0.5 volt, clean the negative cable connections at the battery, the body ground connections and the starter ground connection. Retest.
  4. If the steady voltage drop is greater than 0.5 volt, install a new cable. If the steady voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor.

Scheme 48

Scheme 48: Starter Motor Drive Gear and Flywheel Ring Gear Inspection

Scheme 49

Scheme 49
  1. Check the wear patterns on the starter drive and the flexplate ring gear. If the wear pattern is not normal, install a new starter motor. For additional information, refer to «STARTER MOTOR»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) .
  2. If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or damaged, install a new starter motor. For additional information, refer to «STARTER MOTOR»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) . Install a new flexplate. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) .

Scheme 50

Scheme 50: Starter Motor
ItemPart NumberDescription
1W708960Starter motor lower bolt
2N704942Starter motor upper bolt
3W704941Starter motor stud bolt
411000Starter motor

PARTS DESCRIPTION CHART

Removal and Installation

WARNINGBefore carrying out maintenance on the starting system, disconnect the battery ground cable from the frame to completely isolate the starter from the dual frame-mounted batteries. Failure to follow this instruction may result in serious personal injury.

Scheme 51

Scheme 51

Scheme 52

Scheme 52

Scheme 53

Scheme 53
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
  2. Disconnect the battery ground cable from the frame. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .
  3. Remove the nut and position the cable bracket aside.
  4. Remove the starter solenoid protective cap.
  5. Disconnect the starter motor electrical connections.
  6. Remove the 2 bolts, the stud bolt and the starter.

Scheme 54

Scheme 54: Installation

Scheme 55

Scheme 55
  1. Position the starter motor and install the 2 bolts and the stud bolt in 3 stages. Stage 1: Install the 2 bolts and the stud bolt finger tight. Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft). Stage 3: Tighten the lower bolt and stud bolt to 25 Nm (18 lb-ft).
  2. Connect the starter motor electrical connection. Tighten to 12 Nm (106 lb-in).
  3. Connect the starter motor electrical connection. Tighten to 6 Nm (53 lb-in).
  4. Install the starter solenoid protective cap.
  5. Position the cable bracket and install the nut. Tighten to 25 Nm (18 lb-ft).
  6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#battery-battery-mounting-battery-cables) .