Starting System - Starter - Diesel Ford Econoline I

DESCRIPTION

Note. This article includes Cutaway and RV Cutaway.

The starter used on the 7.3L turbo diesel engine uses internal gear reduction and an externally mounted solenoid. System consists of a ignition switch, starter relay, Digital Transmission Range (DTR) sensor, 2 batteries and wiring.

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TROUBLE SHOOTING

Check the following items before proceeding with testing

1. Check batteries for state of charge.
2. Check cable connections at batteries and starter motor.
3. Ensure transmission is fully engaged in Park or Neutral position.
4. Ensure fuse links "A" and "B" are okay.
5. Check fuse No. 23 (60-amp) in battery junction box and fuse No. 34 (10-amp) in central junction box.

VOLTAGE DROP TEST

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

Scheme 1

1. Remove fuse No. 17 from engine compartment fuse box to disable fuel system. Connect remote starter switch between starter solenoid terminal "S" and positive battery post.
2. Connect positive voltmeter lead to positive battery post, and negative lead to solenoid terminal "M". (Scheme 1)
3. Engage remote starter switch. Voltmeter should indicate.5 volt or less. If voltmeter indicates more than.5 volt, move negative voltmeter lead to solenoid terminal "B". If voltmeter indicates.5 volt or less, go to «STARTER GROUND CIRCUIT TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__starter-ground-circuit-test).
4. Engage remote starter switch. If voltmeter indicates less than.5 volt, solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M". Repeat steps 1 - 4. If voltmeter still indicates more than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Remove and repair or replace solenoid.
5. If voltmeter indicates more than.5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still indicates more than.5 volt at terminal "B", replace battery cable.
6. To locate excessive voltage drop, move voltmeter negative lead toward battery, and check each connection point. When high voltmeter reading disappears, problem is between last connection point and previous connection point.

STARTER GROUND CIRCUIT TEST

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

Scheme 2

1. Remove fuse No. 17 from engine compartment fuse box to disable fuel system. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 2)
2. Connect positive voltmeter lead to starter housing, and negative lead to negative battery post. Engage remote starter switch while observing voltmeter. Voltmeter should indicate.2 volt or less. If voltmeter indicates more than.2 volt, clean negative cable connections at battery and engine.
3. If voltage drop is still excessive, repair or replace negative battery cable and/or engine ground cable as necessary. Repeat starter circuit test after repair to ensure problem has been corrected.

STARTER CURRENT DRAW TEST

Ensure batteries are fully charged. Set parking brake and place transmission in Neutral. Ensure battery connections are clean and tight. Remove fuse No. 17 from engine compartment fuse box to disable fuel system. Clamp inductive ammeter lead around all positive battery cables leading to starter. Crank engine for about 5 seconds and check amperage reading while cranking. Normal amperage draw is 230-630 amps. If amperage draw exceeds specification, replace starter.

SYSTEM TESTS

STARTER DOES NOT CRANK

1. Set parking brake and place transmission in Neutral. Connect a remote starter switch between positive battery terminal and starter relay terminal (Red/Light Blue wire terminal). Press remote starter switch. If starter cranks engine, go to step 4 . If starter does not crank engine, and starter relay did not close, go to next step. If starter did not crank engine, but starter relay closed, go to step 3 .
2. Measure resistance between starter relay case and ground. If resistance is less than 5 ohms, replace relay. Check system operation. If resistance is more than 5 ohms, clean starter relay mounting surface and fasteners. Check system operation.
3. Connect a remote starter switch between positive battery cable and starter motor solenoid "S" terminal (Red wire terminal). Press remote starter switch. If starter does not operate, repair or replace starter motor or solenoid. If starter operates, check for open Red wire between starter relay and starter solenoid. Restore electrical connections and check system operation.
4. Disconnect Transmission Range (TR) sensor connector. Hold ignition switch in START position. Measure voltage between TR sensor harness connector terminal No. 12 (Tan/Red wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair open Tan/Red wire. Restore electrical connections and check system operation.
5. Reconnect TR sensor connector. Hold ignition switch in START position. Measure voltage between TR sensor harness connector terminal No. 10 (Red/Light Blue wire) and ground. If battery voltage exists, repair open Red/Light Blue wire. See «WIRING DIAGRAMS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel) . If battery voltage does not exist, ensure transmission linkage is properly adjusted. If linkage adjustment is okay, replace TR sensor.

STARTER CRANKS SLOWLY

1. Perform «STARTER CURRENT DRAW TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__starter-current-draw-test) under ON-VEHICLE TESTING. If starter passes current draw test, go to next step. If starter fails current draw verify condition of batteries. Battery voltage should be 12 volts or more. Load test batteries 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. Perform «VOLTAGE DROP TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__voltage-drop-test) under ON-VEHICLE TESTING. Repair or replace as necessary. If battery cable voltage drop is .5 volt or less, go to next step.
3. Perform «STARTER GROUND CIRCUIT TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__starter-ground-circuit-test) under ON-VEHICLE TESTING. Repair or replace as necessary. If ground circuit voltage drop is .2 volt or less, go to next step.
4. Perform «STARTER NO-LOAD TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__starter-no-load-test) under COMPONENT TESTS. If current draw is as specified, check engine for mechanical concerns. If current draw is excessive, replace starter motor. Restore electrical connections and check system operation.

UNUSUAL STARTER NOISE

1. Verify starter is installed properly. Check brackets for cracks. Ensure bolts are tight. Repair or replace as necessary. Check system for normal operation. If noise is still present, go to next step.
2. Remove starter motor. See «STARTER MOTOR»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel) under REMOVAL & INSTALLATION. Inspect starter motor and flywheel ring gear for wear or damage. If ring gear is worn or damaged, replace ring gear and inspect starter drive gear. If drive gear is also damaged, replace starter motor. If ring gear and starter motor are okay, perform «STARTER NO-LOAD TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-diesel__starter-no-load-test) under COMPONENT TESTS.

DRIVE PINION TEST

Remove starter from vehicle. See STARTER MOTOR under REMOVAL & INSTALLATION. Rotate drive pinion in both directions. Pinion should free wheel in one direction and lock to armature shaft in the other direction. If pinion free wheels in both directions, replace starter motor.

STARTER NO-LOAD TEST

Remove starter from vehicle. See STARTER MOTOR under REMOVAL & INSTALLATION. Using heavy gauge jumper wires, connect battery positive to starter terminal "B" and negative to starter frame. Connect voltmeter to battery. Clamp inductive ammeter lead around positive cable. Connect remote starter switch between starter solenoid "S" terminal and positive battery terminal. Engage remote starter switch. Starter should turn smoothly. Voltmeter should indicate 11 volts or more, and ammeter should indicate no more than 170 amps. If voltage is lower or current is higher than specification, replace or overhaul starter.

STARTER SOLENOID

Remove starter from vehicle. See STARTER MOTOR under REMOVAL & INSTALLATION. Check resistance between starter motor ground terminal and solenoid case. Resistance should be about .95 ohm. If resistance is not about .95 ohm, replace starter solenoid.

Removal & Installation

Disconnect negative battery cable. Raise vehicle on hoist. Remove starter solenoid terminal cover. Remove starter ground cable nut. Remove lower starter bolts. Remove starter. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

OVERHAUL

Use illustration for exploded view of starter motor assembly. (Scheme 3)

Scheme 3

STARTER MOTOR SPECIFICATIONS

STARTER MOTOR SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starter System Wiring Diagram (Econoline - Diesel - 1999). Scheme 4

Starter System Wiring Diagram (Econoline - Diesel - 2000). Scheme 5

See also:
• STARTER GROUND CIRCUIT TEST
• WIRING DIAGRAMS
• STARTER CURRENT DRAW TEST
• VOLTAGE DROP TEST
• STARTER NO-LOAD TEST
• TORQUE SPECIFICATIONS