Click from starter Relay No start

[Irish Medic 51]

Ok So I had a fuse blow on my 2004 Expedition I removed the fuse box and noticed that relay 203 had the cover missing I replaced the fuse for the radio and replaced the cover on relay 203 and thought I smelt something like when a wire gets overheated I went to start the truck and nothing just a click from the fuse box at the starter relay. Went and bought a new 203 relay and starter relay and replaced them both same result after replacement Towed the truck home replaced the starter thinking that that was the issue and the same result Just a Click.

I have power to everything else and the starter will start and turn over when you go and jump the starter solenoid. I have looked at every fuse in the fuse box and they are good even the 30 amp pink fuses.

Any help would be great is there a secondary fuse box under the hood? Is there another solenoid location
Do I have to replace the fuse box? Where do I start looking I am lost? Also you do not hear the fuel pump engage when you turn the Key I have checked all fuses what am I missing here?

Please HELP !!!

 

[Hamfisted]

If your 203 PCM relay got hot enough to lose it's cover there's likely significant heat damage to the fusebox circuit board and fuel pump relay. You can send it out to get repaired for under $100, or buy a new one for about $350 .


https://www.fordpartsgiant.com/part..._holders_and_circuit_breakers.html?pnc=14A068

 

[Irish Medic 51]

I changed out the fuse box today and still the same result are there any other areas I need to look for relays under the hood or any other areas of the vehicle I can’t keep renting a vehicle I have to have this is my primary mode of transportation I don’t know where else what else to do

 

[riphip]

Can you post a picture of your battery cables/connections? Thanks!!

 

[Irish Medic 51]

Yes

 

[BlackCoffee]

I would do a pinpoint test on the starter circuit. It looks like you have a short and the relay took the brunt of the problem.

Hamfisted makes a good point. When you say jumping the relay turns the starter, does the engine actually start? If not, maybe the secondary fuel pump relay overheated. It is time to pull the fuse box circuit card and give it a good inspection. You can search for videos on replacing the secondary fuel pump relay and they should give a good description of removing the fuse panel by the PAX kick panel. I did replace my relay and it wasn't that difficult.

 

[Irish Medic 51]

We’ve already pulled the fuse box replaced it with a new one so now what will do is it’ll click at PCM Relay then it will click at the starter relay when you go to actually turn the vehicle over so you go from off to accessory you hear the PCM relay click you go to turn all the way over you hear the starter relay click When you’re underneath the vehicle up the gas tank you will hear the fuel pump in engaging I have checked the fusible link of the battery cable if you go to the starter with a screwdriver it will from the solenoid it Will engage the starter

I don’t know where else to look we have tried charging the battery we’ve tried jumping the battery we’ve tried a new battery we’ve cleaned the connections at the starter and battery I don’t know if there’s a release in place else or if something the wiring harness possibly got fried I am totally lost here

 

[Irish Medic 51]

All the relays PCM and starter have been replaced and I have also tried swapping the relays with the starter in other relays in the box and it still does the same thing

 

[BlackCoffee]

I can 't tell from your description if the starter is turning or not. If it is turning, but the engine isn't turning, you may have lost teeth on the ring gear and it is just spinning.
If the starter is not turning it is either power to the solenoid, or power to the armature. Put a voltmeter between the solenoid power terminal and ground. If you get 12 volts between when you turn the key to start, you know the circuit to the solenoid is working. Check to see you have 12 volts on the big cable that comes from the battery to the starter. If not, the link is blown. If you have 12 volts on the solenoid when you turn the key to start, and 12 volts on the big cable, the small connecting wire between the solenoid and the armature may have broken.

 

[Irish Medic 51]

It is turning

 

[Don Hall]

Video re no-start due to loose shifter gear:

 

[Irish Medic 51]

Shifter gear is not loose it was the first thing I did check

 

[Irish Medic 51]

Are there any other relay locations to check ??? Besides the one in the passenger side kick panel ??

 

[Don Hall]

Starter relay......may be old info (?):

 

[Irish Medic 51]

All the fuses and relays were replaced

 

[Irish Medic 51]

The 50 amp fuse is not blown And it has a new fuse box

 

[Don Hall]

Nice option:

 

[Irish Medic 51]

No I’m very familiar with the problems with a 3.5eco-boost is the one in my fiancé’s flex just blew up Two I have a screwed up credit due to a divorce and be getting a loan and another vehicle right now really is not an option as We just bought a house

 

[Don Hall]

No I’m very familiar with the problems with a 3.5eco-boost ..................

I was just being a smart as...

 

[BlackCoffee]

If the starter is turning, it is not the starting circuit or the security module. If the engine is not turning it could be the starter is not engaging or it is the ring gear. If the engine turns, I would look into a fuel condition. Check fuel rail pressure and make sure the fuel cutoff switch is correct.