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Old 01-29-2018, 06:07 PM
mritchie1977 mritchie1977 is offline
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Join Date: Sep 2013
Posts: 251
Default 2003 3.0 No Start, One Click

Hello all,
I'm in need of some immediate help trying to get my daily up and running again.

Two weeks ago it was 19 degrees and truck wouldn't start. Click and nothing. First thought was battery (it was only a year old) so I took it back and put in a new battery. Cleaned up the terminals, started right up.

Next week at a store, same thing. Now I know it's not the battery. Cleaned terminals again, started right up.

Now, I cannot get it to start at all. Yesterday I installed a new starter, but it still will only click with no start. Took that starter back, got another one and bench tested it before installing, it works.

I took a volt meter and I am getting power to both the solenoid ignition and also the heavy gauge power wire. I didn't think to do an ohm test, and if I do I don't know what the readings should be.

My only guess is corrosion under the wire sheath somewhere between the battery and the starter allowing the solenoid to engage but not providing enough juice to engage the starter Does anyone think it might be something else?

i've checked into Motorcraft cables, but it's an entire assembly for $100. Not made of money so I'm guessing I'll have to build a new cable. I've never build cables this large before, so where should I look for either universal pre-built cables or large enough gauge and new ends?

Thank you for your help!
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Oxford White 2003 XLT: Black 36" UWS toolbox, Spray-In Bedliner, Cluster LEDs, Mustang Dome, Sony Headunit, Modded Buggman Bezel, 100% Exterior LEDs, Safari Bar w/ HELLA 500 Driving Lights, 8k HIDs, Air Box Mod, Edge Grill w/ Buggman LED oval, K&N Air Filter
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  #2  
Old 01-31-2018, 07:03 PM
mritchie1977 mritchie1977 is offline
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Join Date: Sep 2013
Posts: 251
Default Re: 2003 3.0 No Start, One Click

Update, took a razor and cut several inches of the rubber sheath off, lump of corrosion 2 inches in. Cleaned with battery cleaner and coated in protectant. I'm on borrowed time, but it starts for now. Has anyone ever replaced the entire harness on these? Should I expect it to be difficult?
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Oxford White 2003 XLT: Black 36" UWS toolbox, Spray-In Bedliner, Cluster LEDs, Mustang Dome, Sony Headunit, Modded Buggman Bezel, 100% Exterior LEDs, Safari Bar w/ HELLA 500 Driving Lights, 8k HIDs, Air Box Mod, Edge Grill w/ Buggman LED oval, K&N Air Filter
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