I am asking this ? Wouldn't such a large drop in voltage indicate that the wire is bad and causing a lot of resistance when the amps are increased?

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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

If your voltage goes 5v on the starter, then one of three things is happening here. Need to know battery voltage with and without the key in start.

1) Your battery is toast. The load of the starter is too much for it resulting in the voltage dropping down to 5v while under load.

2) Something between the battery and the starter is adding a lot of resistance (like a bad cable).

3) The starter is seized up. Voltage drop is due to the massive load of the motor that can't spin.

__________________
(Formerly)
FireRanger
2003 Edge 4.0 4wd

How to: Aux light wiring, relays, & fuses
Info: 300+ intake threads here on FRF
Info: HID Projectors
How To: NO HEAT Troubleshooting Guide

I had the same thoughts and checked voltage drop at battery, none. Took battery in for testing, all OK. Took starter in to test all OK.
Tried to start with jump from other car, same results.
This thing is beating me and pissing me off. LOL.

using Firerangers suggestions that leaves the cable.......rockauto has this part MOTORCRAFT Part # WC9306 More Information About this Part {#F37U14300AJ, F37Z14300C}
[Flag indicates this part fits vehicles manufactured for the US Market. It does not indicate where the part was made -- manufacturers produce parts in multiple factories worldwide.] [Flag indicates this part fits vehicles manufactured for the Canadian Market. It does not indicate where the part was made -- manufacturers produce parts in multiple factories worldwide.] 48 In. Ground Cable

Part Image
$41.89
if you have the 3.0 or 4.0. if you have the 2.3 the parts is $134.maybe you could just replace the one big cable for less money

you really should create a profile of your truck.it makes every thing easier..........

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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

I'm not too familiar with the exact cabling of a '94. Is it one solid uninterupted cable from the battery to the starter? Or is there a fender mounted relay as well? If it is just one long cable, you can probably replace it yourself for much cheaper than buying an official cable.

__________________
(Formerly)
FireRanger
2003 Edge 4.0 4wd

How to: Aux light wiring, relays, & fuses
Info: 300+ intake threads here on FRF
Info: HID Projectors
How To: NO HEAT Troubleshooting Guide

There is a fender mounted relay. I replaced it also. It may be the wires. I am really so tired of this problem.

Did I notice your signature that makes you a pilot?

What engine do you have

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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

2.3L with many many good miles on it.

I wish I had a wiring diagram so I could just tell you where the problem likely is. Does the fender mounted relay switch the primary power to the starter or does it switch the smaller wire that triggers the starter's built in relay? If it switches the primary power, then you should check the voltage at that device as well to narrow down where your high resistance/break is located.

Almost a pilot. Should have that all done this spring sometime when I have funds available.

__________________
(Formerly)
FireRanger
2003 Edge 4.0 4wd

How to: Aux light wiring, relays, & fuses
Info: 300+ intake threads here on FRF
Info: HID Projectors
How To: NO HEAT Troubleshooting Guide

All I will say is check the GROUNDS!!!! Mine did the same thing and replaced all the stuff you did and got the same results. The terminal end on the ground was tight but after closer inspection the cable in the connector was burnt and corroded.

The winner is the ground! The bolt for the main ground on the side of the block had fallen out. Starter works like a champ, it should. But now a new problem. No fire!
Not sure if the new ignition switch is at fault or all the attempts to start with bad ground shorted somewhere else. This engine really runs great and starts easy. Now it won't even fire at all.

Ok well you learned the hard way so no need to pour salt in the wound

Now let's do it right this time. Diagnose then replace. 1st CREATE A DETAILED PROFILE OF YOU TRUCK

Check ecu fuses relay. You need to determine if you have SPARK AND OR FUEL

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2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

OK, ECU fuse relay ? are you talking about the EEC fuse?

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1994 Ranger 2.3L 5spd, 2WD, long bed, standard cab, a/c all original except wore out bench seat and replaced with buckets. owned for 10 years, over 230Kmiles and keeps going! Change all fluids regular. try to do my own maintenance when I can.

nice vehicle profile yes eec=ecu=pcm=puter,etc......if that fuse is blown then you truck would still crank but not have have fuel or spark......if that fuse is fine check for fuel at the shrader valve and check for spark...........you also can spray starter fluid into the throttle body to see if it fires......if it does then you have spark.....

*I think what you have is called a long bed it is not actually 8' also you should add what Cab you have, if you have AC and if you have ABS/RABS......

__________________
2004 Ext Cab, 4WD, 4.0, Auto, 154k. (4.0 engine is out of a 2009 Ranger w/96k) ( as of 7/1/2017)

2004 Ranger, Ext Cab, 2WD, 3.0, 5 speed , 4WABS, crank windows, no cruise, Edge 116k.(6/5,2014) (SOLD).
1999 Ford Ranger, Reg Cab, 2.5, 5 speed, 2WD, no AC, 150k (SOLD).

Ok, will check that. I was hoping for something I may have been changing out to have given the issue. After attempting to start last night. I did smell fuel, I have had problems long ago with fuel inertia switch. so will check pump. I will go through fuses. Is there a possibility that when I installed ignition switch, that it is not adjust properly on the column?

__________________
1994 Ranger 2.3L 5spd, 2WD, long bed, standard cab, a/c all original except wore out bench seat and replaced with buckets. owned for 10 years, over 230Kmiles and keeps going! Change all fluids regular. try to do my own maintenance when I can.