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Old 10-22-2018, 12:28 PM
bigblockfordman bigblockfordman is offline
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Default Help needed - 2002 Ranger electrical gremlin

Hello all. I am working on my sons 2002 Ranger Edge 3.0 liter. Two weeks ago he called me from a gas station and said his truck wouldn't start. I go check it and it appears the battery was dead (4 years old). Tried to jump with no luck so we replaced the battery and it started right up. Four days later no start situation again. The positive terminal cable clamp was corroded so we replaced that and it started right up again.

Two days later, no start yet again. I pulled the starter and checked it with jumper cables and it worked fine. Put it back in, no luck. Replaced the starter and solenoid assembly. No luck. Checked for voltage at the solenoid and got 12.36 volts. Next I replaced the ignition switch (electrical one of the column). Truck started fine several times in a row. Even checked it 30 mins later and it started fine. He drives it to the car wash to vacuum it out and it will not re-start.

There is obviously a gremlin somewhere in the system but I haven't found it yet. Keyswitch seems to have a short as you can push around on it and the door chime will stop. I didn't think there was electrical circuit to that switch (mechanical only) but maybe there is.

Also, I have changed out a relay under the dash that was clicking but the new one clicks too. But not all the time. When that happens the door chime is very muted and almost non-existent. Pull the relay and the door chime is louder like normal.

Looking for some ideas and wiring diagrams for the starter circuit from the ignition switch to solenoid.
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