99 Ford Expedition XLT Click when trying to start

[Charles R Wesley]

So i have a 99 Ford Expedition XLT, have been fighting this issue for a couple of month`s. It started about three months ago I got in my truck and tried to start it. The only thing I got was a click, I know theirs been threads on here discussing a similar issue but never carried out this far.

If i sit there and try to start it 20 maybe 30 times it will kick in and starts fine when it starts. Then i can drive across tow 10 miles run in the store or something and when I come back out half the time it just starts right up like nothing is wrong.
So I replace the starter and it did fine for about two weeks and than issue back again. Took it and had them check the system to isolate. I did and they checked the battery said is was okay but alternator was a bit week. Im game so bought a new alternator. Drove it for two day and issue back again. So had battery checked again and still just fine. So i put back in my old starter to see what would happen and it started fine for about a week than back to square one. I than replace the Solenoid on the fire wall didn`t fix it. So I ran a new ground from frame to starter, new positive wire from battery to starter. and positive wire from battery to solenoid. still same thing. I took starter out again yesturday and took it down to be tested, it work fine 10 times in a row. I have checked the small wire that connect to the S side of the Solenoid key off no juice key on and it`s hot.
Im at a loss at this piont and could really use some input this is driving me nut lol not realy but need to get it resolved. Oh I did tap the starter with a hammer before I took it to get it tested and it started right up. I let it run for a min shut it of and samething over again.

Please Help !!

 

[Bedrck47]

Welcome to the forum

 

[Bedrck47]

Have you tried starting it with the gear shift in Neutral??

 

[Bedrck47]

99 Expy starting circuit print

 

[Charles R Wesley]

Yes I have tried to start it in Neutral still does the same things.

 

[poorboy1964]

Charles Welcome to the forum
really you you have tried everything i would have, it really sounds like a bad connection or wire but you have replaced them, maybe go back through and double check all, sorry not much help.

 

[Bedrck47]

See the print I posted re-check your wiring and also check to make sure fuses are making good contact in the fuse block under the dash Fuse # 20 and #21

 

[Charles R Wesley]

Okay I will check those fuses and see if they are good, and making good contact.

 

[Bedrck47]

You can pull the fuses and take a small tipped screwdriver and push the contact point closer together also clean any contact points

 

[Charles R Wesley]

Okay pulled those two, and replaced with new ones, they seem to be fitting tight when fuse placed back in.

 

[Charles R Wesley]

Also relays 3,4 and 5 i switched them around.

 

[stamp11127]

The next time it doesn't start check the tan/red signal wire at the solenoid for popowewhen the ignition switch is turned to "start".
Do you know how to perform voltage drop testing?
What is your current battery voltage?

 

[Charles R Wesley]

Voltage on Battery is at 12.84/ at the wire connected to the solenoid with key on shows 4.38 amps and whats weird after i turned to key off I accidentally left the leads connected and and it still showing 4.38 amps.

 

[Bedrck47]

Where did you have both leads connected I take it one was at the solenoid where was the other lead connected

 

[stamp11127]

Make sure you have the meter set for dc volts, red lead to wire black lead to chassis ground.

 

[Charles R Wesley]

Okay guys Thanks so Much !! for your help. Problem is solved, i will tell you after going through this i learned a lot about my start system on my Expedition.

So here is what was wrong. I told you how I replaced all the wiring in the the starting system. New alternator, battery always checked good but was beginning to wonder. I had take the starter to where i bought it two month`s ago or so. They rechecked it, in fact he tested it 10 times show passed every-time. I brought it home and it still did the same thing. I double check everything again and was really puzzled. Today I took it to a different auto parts store and they checked it again and it passed about 5 times. One of the guys working there said that thing sounds wrong. I had told them all what I had done to fix the Expedition. He went back and got another stater off the shelve and they hooked it up and this thing sounded like it ran three time faster and sounded much stronger. So i bought the starter and brought it home to put in. The guy even told me if this don`t fix it ill come and work on it for you lol. Got it installed started right up / problem solved, just wanted to let everyone know how it turned out.

Just because they test it and it passes to me now, don`t always mean it`s a good starter. Hopefully this will help someone else as well.

Take Care !!

Charles

 

[stamp11127]

Thanks for the update. Where was the bad starter purchased?
Bench testing a starter only checks the operation in a no load state.

 

[Mike White]

I love updates to solutions!