No crank, no start, just clicks, when it is hot outside?

Tiny
MATT152153
  • MEMBER
  • 2009 FORD FUSION
  • 2.3L
  • 4 CYL
  • 2WD
  • AUTOMATIC
  • 197,000 MILES
Hi there. The car listed above has trouble starting on hot sunny days. All I hear is a click. At night it starts with the first turn of the key. I’ve replaced the battery, the starter, and the smart junction box which contains the starter relay. I tested with a multimeter and whenever I turn the key and it doesn’t start there’s no voltage making it to the starter. I do the same test at night, and I get voltage to the starter, and vehicle starts.
Thursday, September 14th, 2023 AT 3:32 PM

4 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 110,176 POSTS
Hi,

First, I attached the wiring schematic below so that you have a reference. When it doesn't start, which wire on the starter isn't getting power? The larger gauge red should have power at all times. The smaller brown wire with a green tracer should only have power with the key in the start position.

I need to know which wire is being checked.

Also, heat causes metal to expand, so check fuses 2 (60amp) and fuse 14 (15amp) in the under-hood fuse box. Make sure both are clean, tight, and free of corrosion. Additionally, when it won't start, move those fuses around to see if it begins working.

Since you have already replaced the SJB, I will assume the relay and fuse there are both good.

Let me know.

Take care,

Joe

See pics below.
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Thursday, September 14th, 2023 AT 8:19 PM
Tiny
MATT152153
  • MEMBER
  • 3 POSTS
Hey, thanks for the response! I’m going to check out those fuses tomorrow, but to answer your question, I was referring to the smaller brown wire. When I turn the key to start it doesn’t receive voltage and there’s just a click. When it cools down and I turn the key to start it does receive voltage and the vehicle starts up.
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Thursday, September 14th, 2023 AT 9:07 PM
Tiny
MATT152153
  • MEMBER
  • 3 POSTS
Just replaced the 2 fuses mentioned, and it’s still not starting.
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Friday, September 15th, 2023 AT 3:36 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 110,176 POSTS
Hi,

We need to check the starter relay circuit. Take a look through this link, it explains how to test a relay and its circuit:

https://www.2carpros.com/articles/how-to-check-an-electrical-relay-and-wiring-control-circuit

If you remove the relay (when it isn't working), you should find one of the connectors in the box has battery voltage at all times. There will be a second one that should get power when the key is in the start position. Check for that and let me know the results.

Take care,

Joe
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Friday, September 15th, 2023 AT 8:14 PM

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