Mechanics

WILL NOT START.. EXCEPT FOR A PUSH START

2002 Ford Mustang

Electrical problem
2002 Ford Mustang 6 cyl Two Wheel Drive Manual 92000 miles

my 2002 mustang has been having difficulty starting. I thought it was the cold but it did it on warmer days too. Then yesterday I drove home on lunch break fine. On way back to work I stopped at the store for 5 minutes, when I came back out it would not start. I felt the surge of it trying then nothing. And battery gauge was too low. I tried to jump it. That ended up frying a set of jumper cables
when my fried came to get the car for me ( I had to get back to work), he had to push start it and then it ran fine to drive home.
does not seem to be battery. But was told it could be starter or ignition. Any suggestions?
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Tigga1369
December 16, 2008.




Either of these could be the fault. Test the starter first?
TEST A: STARTER DOES NOT CRANK
Verify battery condition. Battery voltage should be 12 volts or more. Load test battery at approximately one-half cold cranking amperage rating. See load tester manufacturer's instructions. If battery is okay, go to next step. If battery voltage is less than 12 volts or loaded battery voltage is less than 9.6 volts, service battery or charging system as necessary.
Measure voltage between positive battery terminal and battery ground cable connection on engine. If battery voltage is present, go to next step. If battery voltage is not present, replace battery ground cable and check for normal system operation.
Measure voltage between battery positive terminal and starter motor housing. If battery voltage is present, go to next step. If battery voltage is not present, verify starter is correctly and tightly installed. If starter installation is okay, remove starter motor and clean mounting surfaces. See STARTER MOTOR under REMOVAL & INSTALLATION. Install starter motor and check system for normal operation.
Measure voltage between starter motor battery cable terminal " B" and ground. See Fig. 3. If battery voltage is present, go to next step. If battery voltage is not present, replace battery positive cable and check for normal system operation.
Fig. 3: Identifying Starter Solenoid Terminals
Courtesy of FORD MOTOR CO.
Momentarily jump starter positive battery cable terminal " B" and start terminal " S" (White/Pink wire). If starter motor operates properly, go to next step. If starter motor does not operate properly, replace starter motor and check system for normal operation. See STARTER MOTOR under REMOVAL & INSTALLATION.
Disconnect starter electrical connector terminal " S" (White/Pink wire). Place transmission in Park or Neutral (A/T), or depress clutch pedal (M/T). Measure voltage between connector terminal " S" (White/Pink wire) and ground with ignition switch in START position. If battery voltage is not present, go to next step. If battery voltage is present, clean starter motor and connector terminals. Check for loose or intermittent connection. Check system for normal operation.
Turn ignition off. Remove starter relay from battery junction box. See Fig. 1. Place transmission in Park or Neutral (A/T), or depress clutch pedal (M/T). Measure voltage between starter relay connector terminal No. 85 (White/Pink wire) and ground with ignition switch in START position. See Fig. 4. If battery voltage is present, go to next step. If battery voltage is not present, go to step 12.
Fig. 4: Identifying Starter Relay Connector Terminals
Courtesy of FORD MOTOR CO.
Turn ignition off. Measure voltage between starter relay connector terminal No. 30 (Light Green/Violet wire) and ground. If battery voltage is present, go to next step. If battery voltage is not present, check fuse No. 3 (40-amp) in battery junction box. If fuse is okay, repair open in Light Green/Purple wire between fuse and starter relay connector and check system for normal operation. See WIRING DIAGRAMS.
Measure resistance between starter relay terminal No. 86 (Black wire) and ground. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Black wire between starter relay connector and ground and check system for normal operation. See WIRING DIAGRAMS.
Measure resistance between starter relay connector terminal No. 87 (Brown/Pink wire) and ground. If resistance is greater than 10,000 ohms, go to next step. If resistance is 10,000 ohms or less, repair short to ground in Brown/Pink wire and check system for normal operation. See WIRING DIAGRAMS.
Measure resistance between starter relay connector terminal No. 87 (Brown/Pink wire) and starter motor connector (White/Pink wire). If resistance is less than 5 ohms, install new starter relay and check system for normal operation. If resistance is greater than 5 ohms, repair open in Brown/Pink wire and/or White/Pink wire. See WIRING DIAGRAMS.
On M/T models, disconnect Clutch Pedal Position (CPP) switch connector. On A/T models, disconnect CPP jumper connector located left of pedal assembly. To identify harness, see WIRING DIAGRAMS. On all models, measure voltage between CPP connector (or jumper connector) Red/Light Blue wire and ground with ignition switch in START position. If battery voltage is present, go to step 14. If battery voltage is not present, go to next step.
Measure voltage between central junction box fuse No. 6 (20-amp) input side and ground with ignition switch in START position. If battery voltage is not present, go to step 17. If battery voltage is present, check fuse No. 6. If fuse is okay, repair Red/Light Blue wire between fuse and CPP connector, (or CPP jumper connector), and check system for normal operation. See WIRING DIAGRAMS.
Measure resistance in White/Pink wire between CPP connector (or CPP jumper connector) and starter relay connector terminal No. 85. If resistance is less than 5 ohms, replace CPP switch (or CPP jumper connector) and check system for normal operation. If resistance is greater than 5 ohms, go to next step (A/T) or repair wire between CPP switch and starter relay connector (M/T). Check system for normal operation. See WIRING DIAGRAMS.
Disconnect Digital Transmission Range (DTR) sensor. Measure resistance between CPP jumper harness connector (White/Pink wire) and DTR sensor connector terminal No. 10 (Red/Light Blue wire). See Fig. 5. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open White/Pink wire and/or Red/Light Blue wire between CPP jumper connector and DTR sensor connector. Check system for normal operation. See WIRING DIAGRAMS.
Fig. 5: Identifying Digital Transmission Range Sensor Harness Connector Terminals
Courtesy of FORD MOTOR CO.
Measure resistance of White/Pink wire between starter relay connector terminal No. 85 and DTR sensor connector terminal No. 12. If resistance is greater than 5 ohms, repair open White/Pink wire between starter relay connector and DTR sensor connector and check system for normal operation. See WIRING DIAGRAMS. If resistance is 5 ohms or less, adjust DTR sensor and recheck. See TRANSMISSION RANGE SENSOR under ADJUSTMENTS. If resistance is still 5 ohms or less, replace DTR sensor and check system for normal operation.
Turn ignition off. Disconnect ignition switch harness connector. Measure voltage between ignition switch harness connector terminal No. B4 and ground. See Fig. 6. If battery voltage is present, go to next step. If battery voltage is not present, check fuse No. 3 (40-amp) in battery junction box. If fuse is okay, repair Light Green/Purple wire between fuse No. 3 and ignition switch harness connector. Check system for normal operation.
Fig. 6: Identifying Ignition Switch Harness Connector Terminals
Courtesy of FORD MOTOR CO.
Measure resistance between ignition switch harness connector terminal STA and central junction box fuse No. 6 input terminal. See Fig. 6. If resistance is less than 5 ohms, replace ignition switch and check system for normal operation. If resistance is 5 ohms or greater, repair White/Pink wire between ignition switch and fuse. Check system for normal operation.

Dave H
Dec 16, 2008.


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