Starting System - Starters - Except Diesel: Diagnosis Ford Econoline E150

TROUBLE SHOOTING

Verify customer compliant by operating starting system. Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral. Check maxi-fuse No. 23 (60-amp) in battery junction box. Check fuse No. 34 (10-amp) in central junction box. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX under SYSTEM TESTS.

TEST B: ENGINE CRANKS SLOWLY

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Turn ignition switch to OFF position. Using DVOM, check voltage between starter motor solenoid terminal "B" and ground. (Схема №1) If voltage is greater than 12.5 volts, go to next step. If voltage is 12.5 volts or less, repair or replace positive battery cable or connections between battery and starter solenoid. Recheck system operation.
3. Perform starter motor ground circuit test. See «VOLTAGE DROP TEST - MOTOR GROUND CIRCUIT»(ref-139515-S04145259142002050100000). If ground is okay, replace starter motor and test system operation. If ground is not okay, repair ground circuit and test system operation. See «WIRING DIAGRAMS»(ref-139515-S08042652162002050100000).

TEST C: UNUSUAL STARTER NOISE

1. Verify starter is installed properly. Ensure bolts are tight. Repair as necessary and check system for normal operation. If starter is mounted properly, go to next step.
2. Connect remote starter switch between starter terminal "B" (Red wire) and starter motor terminal "S" (Red/Light Blue wire). Engage starter motor and verify noise is coming from starter motor. If noise is coming from starter motor, go to next step. If noise is not coming from starter motor, diagnose engine mechanical concern. See appropriate article in ENGINES.
3. Remove starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION. Inspect flywheel ring gear for wear or damage. If ring gear is okay, replace starter motor. If ring gear is worn or damaged, replace ring gear and inspect starter drive gear. If drive gear is also damaged, replace starter motor.

STARTER DRIVE TEST

1. Remove starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION. Secure motor in vise. Using fully charged battery, connect jumper from negative battery terminal to starter motor case. Momentarily connect second jumper from positive battery terminal to starter motor solenoid "S" terminal. (Схема №1) DO NOT leave positive lead of battery connected to starter motor for more than 10 seconds. Verify starter drive ejects. Remove positive jumper from starter motor. Starter drive should return to original position. If starter drive does not eject and return to original position, replace starter motor.
2. Check starter drive. It should turn freely in one direction, and positively engage to armature when rotated in opposite direction. If starter drive does not move as specified, replace starter motor.

STARTER NO-LOAD TEST

1. Remove starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION. Connect remote starter switch between positive battery terminal and starter motor solenoid terminal "S". (Схема №1) Jumper starter motor "B" terminal to positive battery post. Connect charging/starting system tester according to manufacturer's instructions. Ensure battery and starter motor are grounded.
2. Engage remote starter switch. Starter should eject starter drive and turn smoothly. DVOM should indicate 11 volts or more, and ammeter should indicate 70 amps. If voltage is lower or current is higher than specification, replace starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION.

ON-VEHICLE TESTING

STARTER LOAD TEST

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Disconnect inertia fuel shutoff switch connector to prevent vehicle from starting during test. Connect ammeter according to tool manufacturer's instructions. Crank engine while observing ammeter. Current draw should be 130-190 amps. If draw is not as specified, replace starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION.

VOLTAGE DROP TEST - MOTOR FEED CIRCUIT

Note. Make all DVOM connections at component terminal rather than at cable or wire end.

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Disconnect inertia fuel shutoff switch connector to prevent vehicle from starting during test. Connect remote starter switch between positive battery terminal and starter motor relay terminal "S" (Red/Light Blue wire).
3. Connect positive DVOM lead to positive battery terminal and negative lead to starter motor solenoid terminal "M". (Схема №1) Engage remote starter switch and observe DVOM. Voltage should be less than.5 volt.
4. If voltage is greater than.5 volt, move positive DVOM lead to starter motor solenoid terminal "B". (Схема №1) If voltage is now less than.5 volt, go to next step. If voltage is still greater than.5 volt, repair poor positive battery cable connections at battery or starter motor solenoid. If connections are okay, replace positive battery cable.
5. Remove and clean all connections at starter motor solenoid. Install connectors. Repeat test. If voltage is still more than.5 volt at terminal "M" and less than.5 volt at terminal "B", starter motor solenoid is faulty. Remove and repair or replace starter motor. See «STARTER MOTOR»(ref-139515-S08413320402002050100000) under REMOVAL & INSTALLATION.

VOLTAGE DROP TEST - MOTOR GROUND CIRCUIT

Note. Make all DVOM connections at component terminal rather than at cable or wire end.

1. Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
2. Disconnect inertia fuel shutoff switch connector to prevent vehicle from starting during test. Connect remote starter switch between positive battery terminal and starter motor relay terminal "S" (Red/Light Blue wire).
3. Connect positive DVOM lead to starter motor housing and negative lead to negative battery terminal. Engage remote starter switch and observe DVOM. Voltage should be less than .2 volt.
4. If voltage drop is greater than .2 volt, clean negative battery cable connections at battery and chassis. Clean engine ground cable connection at cable mounting bracket. If voltage drop is still excessive, repair or replace battery ground cable.