If it's a no crank conndition it could be starter terminal fatigue, here is the Tech Bulliten, the fix is a new wiring pigtail.
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 2 NO CRANK / STARTER TERMINAL FATIGUE -2004 Ford Pickup Heritage F150
Sunday, April 12th, 2009 AT 6:47 AM