2000 Expy 5.4L - Won't Start

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Mike Darbro

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Good afternoon,

2000 Ford Expedition 5.4L won't start.

About 9 months ago we started seeing n hearing a "click" but no crank.
I changed out the starter and the solenoid. Didn't have any problems since...

Last week, my son drove it, parked it, drove it, parked it and now it won't start, again...

Symptoms:
All electric works, dash lights up, dome lights, head lights are bright.
Upon turning the key the starter "hits" but won't crank the engine. (check for engine seize with wrench on crank - all good)
Tried to "jump the solenoid" with a screw driver - same result - hit but no crank.

Took old starter out, put new in - same result.
Had old starter tested at Advance auto and it appeared to be working so put old starter back in and returned new one...

Now I'm getting info that the starter testers they use may or may not be effective in that it will only show the plunger popping out and spinning but there is no crank meter to ensure its cranking hard enough to turn the engine (is this true?)

Tested the battery - all good...

I'm at a loss here...

TO date, all I have done is replace the solenoid and the result is the same...

Thanks for your time...
 

stamp11127

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Check the ring gear teeth on the flexplate - they might not be there. If they are missing go grab a beer or two.
 
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Mike Darbro

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Pretty sure the ring gear is intact.
Plunger kicks out and engages but does not spin the flywheel...

Just not enough power?

I also tried a direct ground from the battery to the starter...
Same results...
 

stamp11127

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How did you test the battery?
What is the battery voltage currently?
How old is the battery?
How do you know if the drive gear/Bendix is engaging the ring gear?
 

docraymund

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You may have a bad ground wire. It takes a lot more current to spin the flywheel than it does to spin the starter out of the truck.
 
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Mike Darbro

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Batt tester was a OTC 3180 load tester - stayed in green for all tests

Voltage never dropped below 11 even during load test

Batt is 9 months old

How do I know the plunger is hitting the fly wheel - When keyed to start, the starter plunger "hits" the fly wheel hard. Very metal on metal sound and NOT spinning...

Ground - I have tried a direct ground from the battery to the starter and the exact same symptoms as above (forgot I did this earlier...)

I am going to research this grounding thing tho... Sound's like it may be the issue...

Thanks fellas!!
 

stamp11127

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When starters are first energized the current draw is low. Once the bendix has engaged the ring gear the starter is under max torque prior to the movement of the crank. At this point, depending on starter size, the current draw will increase dramatically. In the big truck world the current draw will be in excess of 1200 amps, autos will be less. This is only for an instant, then the current draw drops. You can watch the interior lights when you try to start. If they dim the starter is drawing current. If not, then it isn't receiving it.

In order for the starter to spin the shift lever in the starter has to travel fully out and engage the bendix with the ring gear. Since the teeth may not mesh every time the bendix is spring loaded which allows the shift lever to travel the full length. In doing so the electrical contacts in the starter mounted solenoid make contact sending the high current to the starter windings.

Since you state that the starter isn't spinning I would look at the bendix and solenoid operation. You can test the starter at home if you have jumper cables and a remote start switch.
 
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