Ford had two problems on these, the first one is the easiest to check, look for corrosion at the solenoid where the + battery cable attaches. This is the fix for that:
Disconnect the NEGATIVE cable first, and put it back on LAST!
Here's the second problem:
NO CRANK / STARTER TERMINAL FATIGUE TECHNICAL SERVICE BULLETIN Reference Number(s): 06-19-14, Date of Issue: October 2, 2006 Related Ref Number(s): 06-19-14 ARTICLE BEGINNING ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. PARTS INFORMATION PARTS INFORMATION FORD: 1997-2007 Crown Victoria; 1997-2004 F-150 Heritage; 1997-2006 Expedition; 1998- 2006 E-Series; 1999-2006 F-Super Duty; 2002-2007 Explorer; 2004-2006 F-150; 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator; 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis; 2002-2007 Mountaineer NOTE: TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. NOTE: REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Page 1 of 1 4/8/2010
And the real simple answer is, it could be a weak battery, or poor connections!
Thursday, April 8th, 2010 AT 4:30 PM