Starting System - Starter - Except Diesel Ford Econoline I

DESCRIPTION

Note. This article includes Cutaway and RV Cutaway.

The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral solenoid and has an overrunning clutch in the starter drive. Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission Range (DTR) sensor switch, starter interrupt relay, starter relay diode, and interconnecting cables and wires.

COMPONENT LOCATIONS

COMPONENT LOCATIONS

DIGITAL TRANSMISSION RANGE (DTR) SENSOR

1. Place transmission in Neutral. Raise and support vehicle. Disconnect manual shift control cable. Disconnect DTR electrical connector. Loosen DTR sensor bolts. Using DTR Sensor Alignment Tool (T97L-70010-A), align DTR sensor slots.
2. Tighten DTR sensor bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel) table. Reconnect shift lever control cable. Connect DTR electrical connector. Lower vehicle and check system operation.

TROUBLE SHOOTING

Check the following items before proceeding with testing

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

ON-VEHICLE TESTING

STARTER GROUND CIRCUIT TEST

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

1. Disconnect ignition coil connector from ignition coil to prevent vehicle from starting. Connect remote starter switch between starter solenoid "S" terminal and positive battery post. (Scheme 6) Connect positive voltmeter lead to starter housing, and negative lead to negative battery post.
2. 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 chassis. Also clean engine ground cable connections at front cover and engine mount bracket.
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 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 ignition coil 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»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) under REMOVAL & INSTALLATION.

VOLTAGE DROP 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 ignition coil connector to prevent vehicle from starting during test. Connect remote starter switch between positive battery terminal and starter motor relay terminal (Red/Light Blue wire).
3. Connect positive voltmeter lead to positive battery terminal and negative lead to starter motor solenoid terminal "M". (Scheme 6) Engage remote starter switch and observe voltmeter. Voltage should be less than.5 volt.
4. If voltage is greater than.5 volt, move positive voltmeter lead to starter motor solenoid terminal "B". (Scheme 6) 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. 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»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) under REMOVAL & INSTALLATION.

Scheme 6

Scheme 7

Scheme 8

1. Ensure starter motor is tightly mounted. 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. Inspect battery ground cable connection on starter motor. Repair as necessary. If battery ground cable is okay, measure voltage between positive battery cable connection at starter motor and ground. If battery voltage is present, go to next step. If battery voltage is not present, perform «VOLTAGE DROP TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__voltage-drop-test) under ON-VEHICLE TESTING. Repair or replace positive cable or connections as necessary.
3. Measure voltage between starter motor solenoid terminal "S" and ground with ignition in START position. (Scheme 6) If battery voltage is not present, go to next step. If battery voltage is present, clean and tighten Red wire connections at starter motor and relay and check system operation. If starter motor still does not crank, replace starter motor. See «STARTER MOTOR»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) under REMOVAL & INSTALLATION.
4. Measure voltage between each Red starter motor relay wire and ground. Battery voltage should be present at one Red wire with ignition off. Battery voltage should be present at both Red wires with ignition switch in START position. If voltage is as specified, repair open in Red wire between starter motor relay and starter motor. See «WIRING DIAGRAMS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel). If battery voltage is present on only one Red wire with ignition switch in both OFF and START positions, go to next step. If battery voltage is not present at either Red wire, repair open in Red wire between battery positive terminal and starter motor relay. See «WIRING DIAGRAMS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel).
5. Measure voltage between starter motor relay terminal (Red/Light Blue wire) and ground with ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, check starter motor relay mounting bolts and surfaces for looseness or corrosion. Repair as necessary. If relay is tight and mounting surface is free of corrosion, replace starter relay and check system operation.
6. Disconnect Digital Transmission Range (DTR) sensor connector. Measure voltage between DTR sensor connector terminal No. 12 (Tan/Red wire) and ground with ignition switch in START position. (Scheme 7) If battery voltage is present, go to next step. If battery voltage is not present, go to step 9.
7. Measure resistance of Red/Light Blue wire between DTR sensor connector terminal No. 10 and starter motor relay. (Scheme 7) If resistance is less than 5 ohms, go to next step. If resistance is greater than 5 ohms, repair open in Red/Light Blue wire and check system operation.
8. Check connections for looseness or corrosion. If connections are okay, adjust DTR sensor, reconnect all connectors and check system operation. See «DIGITAL TRANSMISSION RANGE (DTR) SENSOR»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__digital-transmission-range-dtr-sensor) under ADJUSTMENTS. If starter still does not crank, replace DTR sensor and check system operation.
9. Reconnect DTR sensor connector. Remove and inspect central junction box fuse No. 34 (10-amp). If fuse is okay, go to step 11. If fuse is blown, install new fuse and check system operation. If fuse blows again, check for short to ground between fuse No. 34 cavity (output side) and starter motor relay. Disconnect Red/Light Blue wire from starter motor relay and check resistance between fuse No. 34 cavity (output side) and ground. If resistance is greater than 10,000 ohms, replace shorted starter motor relay. If resistance is still less than 10,000 ohms, go to next step.
10. Disconnect DTR sensor connector and check resistance between fuse No. 34 cavity (output side) and ground. If resistance is less than 10,000 ohms, repair short in Tan/Red wire. See «WIRING DIAGRAMS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel). If resistance is greater than 10,000 ohms, measure resistance between DTR sensor connector terminal No. 10 and ground. (Scheme 7) If resistance is less than 10,000 ohms, repair short to ground in Red/Light Blue wire. See «WIRING DIAGRAMS»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel). If resistance is greater than 10,000 ohms, install new DTR sensor and check system operation.
11. Measure voltage between fuse No. 34 cavity (input side) and ground with ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, repair or replace central junction box or open Tan/Red wire between central junction box and DTR sensor connector.
12. Disconnect ignition switch harness connector. Measure voltage between each ignition switch connector terminal BATT (Yellow wires) and ground. If battery voltage is not present, go to step 14. If battery voltage is present, go to next step.
13. Measure resistance of ignition switch between terminals BATT (either one) and ST with ignition switch in START position. (Scheme 8) If resistance is greater than 5 ohms, replace ignition switch and check system operation. If resistance is 5 ohms or less, check connectors for looseness or corrosion. If connections are okay, check for open in White/Pink wire between ignition switch connector and central junction box. If wire is okay, repair or replace central junction box.
14. Reconnect ignition switch connector. Remove and inspect battery junction box fuse No. 23 (60-amp). If fuse is okay, go to step 16. If fuse is blown, replace fuse and check system operation. If fuse blows again, short to ground is present between battery junction box fuse No. 23 and central junction box fuse No. 34, (resistance to ground is less than 10,000 ohms). Disconnect ignition switch connector and recheck resistance. If resistance is greater than 10,000 ohms, go to next step. If resistance is still less than 10,000 ohms, repair short to ground in appropriate Yellow wire. For power distribution wiring diagrams, see appropriate wiring diagram in POWER DISTRIBUTION article in WIRING DIAGRAMS.
15. Measure resistance of ignition switch between each BATT terminal and ground in every switch position. (Scheme 8) If resistance is less than 10,000 ohms in any switch position, replace ignition switch and check system operation. If resistance is greater than 10,000 ohms, repair short to ground in White/Pink wire between ignition switch and central junction box.
16. Repair open in power distribution circuit. See appropriate wiring diagram in POWER DISTRIBUTION article in WIRING DIAGRAMS. Check system operation.

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. (Scheme 6) 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 ground circuit test. See «STARTER GROUND CIRCUIT TEST»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-ground-circuit-test) under ON-VEHICLE TESTING. If ground is okay, replace starter motor. Recheck system operation. If ground circuit is not okay, repair ground circuit as necessary. Recheck system operation.

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 positive battery terminal and starter motor relay terminal 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 engine article in ENGINES.
3. Remove starter motor. See «STARTER MOTOR»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) 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»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) 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. (Scheme 6) 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»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) under REMOVAL & INSTALLATION. Connect remote starter switch between positive battery terminal and starter motor solenoid terminal "S". (Scheme 6) 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. Voltmeter should indicate 11 volts or more, and ammeter should indicate 60-80 amps. If voltage is lower or current is higher than specification, replace starter motor. See «STARTER MOTOR»(/ford/econoline/i-1985-2013/remont/starter/#starting-system-starter-except-diesel__starter-motor) under REMOVAL & INSTALLATION.

STARTER MOTOR

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Remove starter solenoid terminal cover. Disconnect starter solenoid wire connections. Remove starter motor mounting nut and ground cable. Remove starter motor mounting bolts. Remove starter motor. To install, reverse removal procedure. Ensure negative battery cable is reinstalled to starter mounting bolt. Tighten bolts to specification. See TORQUE SPECIFICATIONS table.

STARTER MOTOR SPECIFICATIONS

STARTER MOTOR SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starter System Wiring Diagram (Econoline - Except Diesel). Scheme 9

See also:
• TORQUE SPECIFICATIONS
• STARTER MOTOR
• VOLTAGE DROP TEST
• DIGITAL TRANSMISSION RANGE (DTR) SENSOR
• STARTER GROUND CIRCUIT TEST
• TORQUE SPECIFICATIONS