Occasional Long Crank

[newexpyguy]

Hi Everyone, first post here, looking for some help.

For about a year now my wife's 03 5.4l expy has been having an occasional long crank when starting up. There seems to be no rhyme or reason when it will happen, sometimes it is hot or a cold start, sometimes it is when the tank is empty, others full, others half full. Of a possible 30 starts per week it probably happens 10 times. Enough to be annoying but not a problem...yet which is what I'm concerned about.

It always starts up when this happens, just cranks (almost seems like something skips) but then turns over and goes.

With the help of my brother in law (who was a Ford mechanic for a short time) I've replaced the fuel pump, crank sensor, cam sensor, spark plugs, battery and IAC none of which have fixed the problem.

I've never had a code pop up while we've owned the truck (about two years). It has 200,000km on it approx 125,000 miles so am hoping to get lots more mileage out of this beast.

Any ideas? I'm completely stumped and at a loss for ideas...

Thanks!

 

[stamp11127]

Welcome to the site. The 03's have issues with the fusebox and fuel pump circuit. I would take a fuel pressure reading prior to inspecting the pcb in the fusebox. Of course take the reading when the no start occurs.

 

[barricade]

I have an 04 with the same issue. Only time it starts on a short crank is after it's sat more than 8+ hours. I'm at 130k miles

 

[Dnny44]

Barricade My 04 Has this exact same problem and just about 130,000 miles too. Our family mechanic thinks it has something to do with the fuel regulator.

 

[46L281GT]

I had the same issue on my 04 5.4 with 120,000. I replaced a COP a few days ago and so far haven't had an issue. I will report back if that changes.

 

[Dnny44]

sorry not a guru what is a COP?

 

[Skauber]

Coil-On-Plug, it's those 8 black things that sits on top of your spark plugs.

 

[Dnny44]

Ahah thank you

 

[WarrenG]

I have had the same issue with mine. Haven't taken it into the shop yet, but I noticed if I turn off my heater/ac starts fine. not sure why or if that is just a coincidence.
04' w/ 5.4

 

[newexpyguy]

How long does it take to change the COPs? Any youtube links that show how to do it? Thanks for the reply's.

 

[46L281GT]

Super easy, just need a 8 mm I think. The back ones are kinda difficult to get to, but not too bad. Just look up 5.4 spark plug replacement on YouTube

 

[newexpyguy]

After checking the coil packs (which all checked out ok), I decided to replace the Throttle Position Sensor, which solved the problem. No more long cranks at all, the engine fires right up. Not sure why a code wasn't triggered but seems like it was the faulty TPS which was the problem.

 

[onlyexilove]

How long does it take to change the COPs? Any youtube links that show how to do it? Thanks for the reply's.

The COPS usually take me about and hour to 1.5 hours. Depending on skill level it could take upwards of 3-4 hours.

You will need the following tools:
1/4 inch socket wrench
7mm deep well or short well socket
extension (probably good with a pair of 6 inch extensions and a shorty extension)
1/4 inch swivel
extendable magnetic tool
flashlight or shop light

The biggest pains to remove will be the number 4 (passenger side in the very back under the firewall) and the number 8 (driver side in the very back underneath the fuel lines).

I would suggest to wear long rubber gloves due to the fiberglass insulation located on the firewall which is where your arm will rub trying to get to the number 4 COP. The connectors for all of the COPs are press in connectors and easy to remove. I would suggest removing them first before removing the COPs.

You will find a single 7mm small bolt that holds down the COPs to the intake manifold and there is only 1 bolt per COP.
Remove the bolts and then you should be able to reach the boot on the COP and remove then that way or even pull on the plastic top of the COP to remove them.

It is always best to use plenty of dielectric grease when installing the new ones to ensure that moisture stays out of the connection. During installation make sure to press down firmly on each one during installation to ensure the end of the coil wire connects to the top of the spark plug and then reinstall the 7mm bolt

I hope this helps!

 

[panetta6pack]

Long crank

I have the same issue but I was told there is a check valve in the fuel pump that would fail causing the fuel to loose prime ? is this possible ? I will replace the TPS for the 50 bucks or so but any feed back would help.

 

[Wilson]

Mine long cranks when HOT only. Dealership said it was the fuel pressure regulator located on the driver side, halfway back on the engine. I replaced that, but still get long crank when hot.

There is also a vacuum tube coming off of the top of the FPR, so I'm thinking that could be the culprit since I had had some issues with the vacuum storage canister and a couple of vacuum lines.

Cold start is instant.

 

[1955moose]

Wilson this post is 1 1/2 years old, if the op doesn't care to update, don't bother. He's either gone or dead!


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[Snag]

Moose, I guess an occasional long crank is a good thing, but if you have a slow start when hot you are in trouble

 

[1955moose]

Does that go with, you in long, you in hard, you indecent!


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