Starter solenoid/relay location 2003

[johnboneske]

Where is the relay/solenoid located on my 2003?

The problems NEVER cease to exist on my expedition...

Was outside this morning, its raining and the damn truck started starting itself... The doors are were locked, no key in the ignition, etc. So, I crapped myself, ran into the garage, got a wrench and disconnected the positive terminal.

So far I removed the #1 relay inside and tried to apply power...still tries to start. Then pulled fuse #101, and tried again, still tries to start itself. On my old expedition(1997) the the starter had a solenoid on the starter itself. Is there a separate location on the firewall/fender for a solenoid or relay? I cant get the damn thing in the garage, since the camper is in the driveway. Cant get the camper out of the driveway without the truck... So, have to wait till it quits raining! I am hoping the the positive wire is loose on the starter and is touching the starter solenoid terminal(probably not likely though).

When it rains it pours... no pun intended!!

 

[R W Carpenter]

I will PM you the appropriate service manual section. See page 7.

 

[Plati]

Is there any chance your wife is in the house watching with the remote starter getting even with you for something?

A few years ago I convinced my nephews I could start my Expy just by thinking about it.
The poor kids may be scarred for life. I'm a bad uncle.

Just kidding about the wife thing.
Cant wait to hear what this is.
I think an Exorcism is required.

...might be worth googling it also

 

[R W Carpenter]

Where is the relay/solenoid located on my 2003?

The problems NEVER cease to exist on my expedition...

Was outside this morning, its raining and the damn truck started starting itself... The doors are were locked, no key in the ignition, etc. So, I crapped myself, ran into the garage, got a wrench and disconnected the positive terminal.

So far I removed the #1 relay inside and tried to apply power...still tries to start. Then pulled fuse #101, and tried again, still tries to start itself. On my old expedition(1997) the the starter had a solenoid on the starter itself. Is there a separate location on the firewall/fender for a solenoid or relay? I cant get the damn thing in the garage, since the camper is in the driveway. Cant get the camper out of the driveway without the truck... So, have to wait till it quits raining! I am hoping the the positive wire is loose on the starter and is touching the starter solenoid terminal(probably not likely though).

When it rains it pours... no pun intended!!

The Solenoid (according to the service manual) is located on the Starter.

 

[1955moose]

John your starter solenoid is located below your battery tray. Easiest way is follow positive cable coming off battery. You've had a lot of rain lately it sounds like. My 2000 starting cranking while running, but mine has the Gem module that was getting wet, shorting all kinds of things. I believe your year has a smart junction box that possibly got wet. The other possibility is your ignition switch electrical part shorted, or key tumbler is stuck. You'll need to do a little more detective work sorry to say.

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[Big Brian]

NEVER under any circumstances disconnect your positive battery terminal first! Always do the negative one.

The reason is if you touch ground with your wrench while working on the positive terminal you create a dead short and could cause the battery to explode or just arc weld the wrench to the grounded part you touched

So get into the habit anytime you disconnect the battery always do the negative one first

mechanics 101

 

[R W Carpenter]

NEVER under any circumstances disconnect your positive battery terminal first! Always do the negative one.

The reason is if you touch ground with your wrench while working on the positive terminal you create a dead short and could cause the battery to explode or just arc weld the wrench to the grounded part you touched

So get into the habit anytime you disconnect the battery always do the negative one first

mechanics 101

Completely true. I missed that in his original post.

 

[Big Brian]

Completely true. I missed that in his original post.

Was just a friendly reminder for anyone reading along

 

[1955moose]

But when adrenaline is pumping like a short taking place you grab that 8 mm and yank that cable. You don't even look at what cable your disconnecting. No, stopping the smoke or Sparks is paramount at that moment. It's happened to every mechanic at least once. Usually it's from some other bonehead that shorted out something, and its panic time your on deck to stop the emergency!

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[Big Brian]

It's also the reason positive DC power is always marked red

I would never grab for the battery positive but that's because it's drilled into what's left of my gray matter

Not blaming you for what you did just thought I would state the correct safe way for anyone reading along

 

[1955moose]

Unless the parts store sells you a black cable cause he's out of the red licorice!

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[R W Carpenter]

Unless the parts store sells you a black cable cause he's out of the red licorice!

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In which case you go to a different parts store. Red electrical tape works too.

 

[Big Brian]

My point is red is the electric code for positive for a reason

 

[1955moose]

I know just funnin! You'd be surprised how many cars I've worked on that had the cable colors reversed. Imagine the fun when an inexperienced person tries to jump start that vehicle at night.

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[Big Brian]

My first wrenching job was at Kmart when I was a kid we used to put a battery in a shopping cart and jump start people in the parking lot when they had a dead battery

One time the guy I worked with jumped someone at night and was not paying attention

He reversed the terminals and the battery exploded in his face

He was permanently scarred

I will never forget it

That's one reason I take this kind of thing seriously I have witnessed what can happen

 

[1955moose]

My first job was at Arco gas. Worked Friday, Saturday night swing shift. We had a moving dolly with battery bungie corded down. On rainy nights I remember walking 2-3 blocks to jump start cars. I was taught early on positive from negative. I filled batteries in those days, they were shipped dry like motorcycle batteries. Mean stuff electrolyte acid. Early on learned safety glasses too!

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[johnboneske]

So far... havent been able to do much since it is outside and cant get it in my garage since camper is in driveway (still raining). The positive terminal is disconnected. First: I removed the cable that goes under my battery tray(which I assume goes to the Solenoid) from the "bundle" on the positive battery terminal. Re attached the battery terminal and still tries to start. I reattached it after it didnt work. Second: I had my wife sit in my truck, turn the key to the run position, and I connected the terminal to the positive, and it turns over and starts. Remove the positive terminal and it runs obviously since the alternator provides power. But, I can hear the starter is still engaged to the flywheel. I am assuming the starter is bad or the solenoid on it, which I should just do the starter then...

I understand what you are saying taking off the positive vs negative cable and agree, rest assured I am a Master Electrician by trade... I know accidents happen but am VERY careful! I have worked with 4160 Volys before @ 300 amps... I understand! I do know Volts vs amps and AC vs DC and all that is entailed. Thank you though for your concern, it means alot to be "thought about" and knowing you dont want me hurt!

Any other help/thought would be appreciated!

 

[1955moose]

Test the lead from ignition switch to starter solenoid. Should only have 12 volts when you turn the key to the crank position. If you have 12 volts without touching key, you've got a stuck key tumbler, or shorted ignition switch. Try lightly whacking your starter relay, both under battery, and on top of starter, you have 2 one may be stuck open. You'll have to jack passenger side to gain access to lower one.

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[johnboneske]

Of course, I have to ask.. would the ignition switch contacted to turn over without me touching anything? I can understand it would, if I turned the key and it could get stuck in the on/start position. But, everything else with the key switch works properly, so I would assume its the solenoid under the battery or the starter itself. If I disconnect the solenoid under the battery and it still tries to start itself( since the positive terminal wire goes directly to the starter) wouldnt it point the the starter itself? Why would Ford put two solenoids on it? Isnt that redundant?

On my positive battery terminal there are 3 thick wires. Id say one is 2 gauge and the other two are 4 gauge. I assume the 2 gauge goes directly to the starter... One that is 4 goes under/towards the battery and the other to the top side of the engine, assuming alternator. As I said, its raining...hard to work in the rain...

 

[1955moose]

I always wondered why 2 solenoids myself. It's not as if these motors are super high compression or horsepower. Maybe one of the others could elaborate why, I'm curious myself. I'm guessing one of the solenoids is stuck open, that's why the light smack, rubber mallet would be best. One of the plungers might be stuck!

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