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Starters Ford Explorer Sport Trac I

Starter 14 illustrations ~2414 words

DESCRIPTION

The starter motor is equipped with an externally mounted solenoid. Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission Range (DTR) sensor (A/T) or Clutch Pedal Position (CPP) switch (M/T), starter relay and interconnecting cables and wires. Starter relay is controlled by the Powertrain Control Module (PCM).

COMPONENT LOCATIONS

ComponentLocation
Battery Junction BoxLeft Side Of Engine Compartment
Central Junction BoxBehind Left Side Of Instrument Panel
Clutch Pedal Position SwitchOn Clutch Pedal Bracket
Digital Transmission Range SensorLeft Side Of Transmission
Inertia Fuel Shutoff SwitchBehind Right Kick Panel
Powertrain Control ModuleCenter Rear Of Engine Compartment
Starter RelayIn Battery Junction Box

COMPONENT LOCATIONS

DIGITAL TRANSMISSION RANGE SENSOR

  1. Raise and support vehicle. Disconnect manual shift control cable. Disconnect Digital Transmission Range (DTR) sensor harness connector. Remove manual control lever nut. Remove manual control lever. Loosen DTR sensor bolts.
  2. Manual shift lever must be in Neutral. Using DTR sensor Alignment Tool (T97L-70010-A), align DTR sensor slots. Tighten DTR sensor bolts evenly. Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Install manual shaft outer nut. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters__torque-specifications) . Connect shift lever control cable. Connect DTR sensor harness connector. Verify that the shift cable is adjusted correctly.

TROUBLE SHOOTING

Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral (A/T) or clutch pedal is fully depressed (M/T). Vehicles built before 2/18/02, check fuse No. 24 (7.5-amp) in central junction box. Vehicles built after 2/18/02, check fuse No. 4 (7.5-amp) in central junction box. On all models, check fuse No. 11 (50-amp) in battery junction box. Ensure anti-theft system is operating properly. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT for additional information. If problem is found, repair as necessary. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

SYSTEM TESTS

SymptomPerform Test
Engine Does Not Crank Or Relay ClicksA
Unusual Starter NoiseB
Engine Cranks Slowly(1)
Starter Spins But Does Not Crank Engine(2)
(1) Perform VOLTAGE DROP TEST under ON-VEHICLE TESTING. (2) Inspect starter motor mounting. Inspect flywheel ring gear and starter motor gear for damaged and missing teeth. Repair or replace components as necessary.
(1)Perform VOLTAGE DROP TEST under ON-VEHICLE TESTING.
(2)Inspect starter motor mounting. Inspect flywheel ring gear and starter motor gear for damaged and missing teeth. Repair or replace components as necessary.

SYMPTOM INDEX

TEST A: ENGINE DOES NOT CRANK OR RELAY CLICKS

  1. Ensure battery is fully charged and has sufficient capacity. If battery is okay, go to next step. If problem exists, repair charging system and/or replace battery as necessary.
  2. Measure voltage between positive battery post and battery ground cable connection at engine block. If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, replace battery ground cable. Check system operation.
  3. Measure voltage between positive battery post and starter motor case. If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, clean starter motor mounting flange and ensure starter motor is properly mounted. Check system operation.
  4. Turn ignition off. Measure voltage between starter motor solenoid terminal "B" (Red wire) and ground. (Scheme 1) If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, replace positive battery cable. Check system operation.
  5. Momentarily connect a jumper wire between starter motor solenoid terminals "B" (Red wire) and starter motor solenoid terminal "S" (Yellow/Light Blue wire). (Scheme 1) If starter motor engages and cranks engine, go to next step. If starter motor does not engage and crank engine, replace starter motor. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) under REMOVAL & INSTALLATION.
  6. Disconnect starter motor solenoid terminal "S" harness connector. Hold ignition switch in START position. Measure voltage between ground and starter motor solenoid terminal "S" (Yellow/Light Blue) harness connector. If voltage is less than 10 volts, go to next step. If voltage is greater than 10 volts, clean starter solenoid terminal "S" and connector. Check wiring and starter motor for loose or intermittent connection. Check system operation.
  7. Turn ignition off. Remove starter relay from Battery Junction Box (BJB). BJB is located on left side of engine compartment. Hold ignition switch in START position. Measure voltage between ground and starter relay connector terminal No. 85 (Tan/Red wire). (Scheme 2) If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, go to step 13.
  8. Turn ignition off. Measure voltage between starter relay connector terminal No. 30 (Yellow wire) and ground. If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, repair power distribution circuit as necessary. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  9. Ensure starter motor solenoid "S" terminal harness connector is disconnected. Measure resistance between ground and starter relay connector terminal No. 87 (Yellow/Light Blue wire). If resistance is 10 k/ohms ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Yellow/Light Blue wire between starter relay and starter motor solenoid. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  10. Measure resistance in Yellow/Light Blue wire between starter relay connector terminal No. 87 and starter motor solenoid "S" harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/Light Blue wire between starter relay starter motor solenoid. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  11. Install starter relay. Connect starter motor solenoid "S" terminal harness connector. Disconnect Powertrain Control Module (PCM) harness connector 175. Connect a jumper wire between ground and PCM harness connector terminal No. 44 (Dark Blue/Orange wire). (Scheme 3) Hold ignition switch to START position. If engine does not crank, go to next step. If engine cranks, repair anti-theft system as necessary. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.
  12. Turn ignition off. Remove starter relay. Measure resistance in Dark Blue/Orange wire between PCM harness connector terminal No. 44 and starter relay connector terminal No. 86. (Scheme 2)and (Scheme 3). If resistance is less than 5 ohms, replace starter relay. If resistance is 5 ohms or more, repair open in Dark Blue/Orange wire between starter relay and PCM. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters).
  13. Hold ignition switch to START position. Vehicles built before 2/18/02, measure voltage between ground and input side of fuse No. 24 in central junction box. (Scheme 4) Vehicles built after 2/18/02, measure voltage between ground and input side of fuse No. 4 in central junction box. (Scheme 5) On all models, if voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, go to step 15.
  14. Disconnect Digital Transmission Range (DTR) sensor 12-pin harness connector. Measure voltage between ground and DTR sensor harness connector terminal No. 12 (Pink wire). (Scheme 6) If voltage is greater than 10 volts, go to step 20. If voltage is less than 10 volts, go to step 18.
  15. Disconnect ignition switch harness connector. Measure voltage between ground and ignition switch harness connector terminal B4 (Yellow wire). (Scheme 7) If voltage is greater than 10 volts, go to next step. If voltage is less than 10 volts, repair open or short in Yellow wire between ignition switch and battery junction box. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  16. Vehicles built before 2/18/02, measure resistance in Red/Light Blue wire between ignition switch harness connector terminal STA and input side of central junction box fuse No. 24. (Scheme 4)and (Scheme 7). Vehicles built after 2/18/02, measure resistance in Red/Light Blue wire between ignition switch harness connector terminal STA and input side of central junction box fuse No. 4. (Scheme 5)and (Scheme 7). On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red/Light Blue wire between ignition switch connector and central junction box. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  17. Measure resistance between ground and ignition switch harness connector terminal STA (Red/Light Blue wire). If resistance is 10 k/ohms or more, replace ignition switch and check system operation. If resistance is less than 10 k/ohms, repair short to ground in Red/Light Blue wire between ignition switch connector and central junction box. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  18. Vehicles built before 2/18/02, measure resistance in Pink wire between DTR sensor harness connector terminal No. 12 (Pink wire) and output side of central junction box fuse No. 24. (Scheme 4)and (Scheme 6). Vehicles built after 2/18/02, measure resistance in Pink wire between DTR sensor harness connector terminal No. 12 (Pink wire) and output side of central junction box fuse No. 4. (Scheme 5)and (Scheme 6). On all models, if resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Pink wire between DTR sensor connector and central junction box. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  19. Vehicles built before 2/18/02, measure resistance between ground and output side of central junction box fuse No. 24. Vehicles built after 2/18/02, measure resistance between ground and output side of central junction box fuse No. 4. On all models, if resistance is 10 k/ohms or more, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Pink wire. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  20. Measure resistance of Tan/Red wire between starter relay connector terminal 85 and DTR sensor harness connector terminal No. 10. (Scheme 2)and (Scheme 6). If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Tan/Red wire between DTR sensor and starter relay. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.
  21. Measure resistance between ground and starter relay connector terminal No. 85 (Tan/Red wire). If resistance is 10 k/ohms or more, check DTR sensor adjustment. See «DIGITAL TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters__digital-transmission-range-sensor) under ADJUSTMENTS. If DTR sensor is adjusted properly, replace DTR sensor. Check system operation. If resistance is less than 10 k/ohms, repair short to ground in Tan/Red wire between DTR sensor and starter relay. See «WIRING DIAGRAMS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters). Check system operation.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

TEST B: UNUSUAL STARTER NOISE

  1. Verify starter is installed properly. Ensure bolts are tight. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters__torque-specifications). 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 solenoid terminals "B" and "S". (Scheme 1) 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.
  3. Remove starter motor. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) under REMOVAL & INSTALLATION. Inspect flywheel ring gear for wear or damage. (Scheme 8) 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.

Scheme 8

Scheme 8
Scheme 8

STARTER RELAY

  1. Remove starter relay from battery junction box. Check relay continuity. Continuity should exist between relay terminals No. 85 and 86, and between relay terminals No. 30 and 87a. (Scheme 9) Continuity should not exist between relay terminals No. 30 and 87. If continuity is as specified, go to next step. If continuity is not as specified, replace relay.
  2. Disconnect the ohmmeter. Connect terminals No. 30 and 85 to a 12 volt DC power and terminal No. 86 to ground. Measure voltage between terminal No. 87 and 86. If voltage is 12 volts, continue the test. If voltage is not 12 volts, replace the relay. Disconnect power from terminal No. 85 and measure voltage between terminal No. 87a and 86. If the voltage is 12 volts, the relay is okay. If not, replace the relay.

Scheme 9

Scheme 9
Scheme 9

ON-VEHICLE TESTING

CAUTIONWhen the battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Before testing starter, ensure transmission is in Park or Neutral.

VOLTAGE DROP TEST

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

Scheme 10

Scheme 10: VOLTAGE DROP TEST
Scheme 10: VOLTAGE DROP TEST
  1. Ensure battery is fully charged. Disconnect inertia fuel shutoff switch to prevent vehicle from starting. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. Connect positive voltmeter lead to positive battery post, and negative lead to solenoid terminal "M". (Scheme 10)
  2. Engage remote starter switch. If voltmeter indicates.5 volt or less, go to «STARTER GROUND CIRCUIT TEST»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters__starter-ground-circuit-test). If voltmeter indicates greater than.5 volt, go to next step.
  3. Move negative voltmeter lead to solenoid terminal "B". Engage remote starter switch. If voltmeter indicates less than.5 volt, the solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M". Repeat steps 1 - 3.
  4. If voltmeter still indicates more than.5 volt at terminal "M" and less than.5 volt at terminal "B", solenoid contacts are bad. Replace starter motor. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) under REMOVAL & INSTALLATION. If voltmeter indicates greater than.5 volt at terminal "B", clean cables and connections at solenoid. Retest.
  5. If voltmeter still indicates greater than.5 volt at terminal "B", check for poor positive battery cable connection or bad cable. By moving the voltmeter negative lead toward the battery and checking each mechanical connection point, the excessive voltage drop can be located. When the high reading disappears, the last mechanical point that was checked is the concern. Repair or install a new connection as necessary.

STARTER GROUND CIRCUIT TEST

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

  1. Disconnect inertia fuel shutoff switch to prevent vehicle from starting. Connect remote starter switch between starter solenoid terminal "S" and positive battery post. (Scheme 11) 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 greater than.2 volt, clean negative cable connections at battery and engine. Retest.
  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.
  4. If the voltage reading is less than.2 volt and starter motor still cranks slowly or not at all, replace starter motor. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) under REMOVAL & INSTALLATION.

Scheme 11

Scheme 11
Scheme 11

REMOVAL & INSTALLATION

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
WARNINGWhen carrying out maintenance on the starting system be aware that heavy gauge leads are connected directly to the battery. Make sure protective caps are in place when maintenance is completed.

Note. Four wheel drive vehicles, remove the bolts and position aside the front axle dampener (if equipped). (Scheme 12)

Disconnect negative battery cable. Raise and support vehicle. Remove starter motor solenoid terminal cover. Disconnect starter solenoid wire connections. (Scheme 13) Remove the nut and the starter ground cable. (Scheme 14) Remove starter motor bolts and starter. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

STARTER MOTOR SPECIFICATIONS

ApplicationSpecification
Cranking Speed (Normal Load)140-220 RPM
Current Draw
Maximum Load800 Amps
No Load60-80 Amps
Normal Load130-220 Amps
Maximum Starter Circuit Voltage Drop.5 Volt

STARTER MOTOR SPECIFICATIONS

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Front Axle Dampener Bolts52 (70)
Starter Motor Ground Cable Nut16 (22)
Starter Motor Mounting Bolts18 (25)
INCH Lbs. (N.m)
Solenoid "B" Terminal Nut106 (12)
Solenoid "M" Terminal Nut106 (12)
Solenoid "S" Terminal Nut53 (6)

TORQUE SPECIFICATIONS

EXPLORER SPORT

For starter system wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

For power distribution system wiring diagram, see POWER DISTRIBUTION in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

EXPLORER SPORT TRAC

For starter system wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

For power distribution system wiring diagram, see POWER DISTRIBUTION in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.