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Automotive/Ford Ranger Not Starting

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Expert: - 11/24/2010


Question
I have a 1999 Ford Ranger 3.0 Flex fuel 4x2.  The problem occurs when I try to start.  I have a new battery.  All the lights come on and such.  When I attempt to crank, I get nothing.  I have been told it's the starter by several friends.  My father doesn't think it's the starter.  Sometimes it will crank, other times it won't.  I can start it and drive to one destination...usually wait 20-30 minutes and it will start again.  Sometimes though, I have had to wait overnight for it to crank again.  I have changed out the battery terminals thinking that might be the problem because of corrosion.  That didn't fix it.  I am wondering if maybe its just the starter solenoid or if it is actually the starter itself.  When I turn the key over, everything comes on so I know I'm getting power.  But it does nothing to attempt to start.  It makes no noise. Can you make any suggestions?

Answer
I can suggest that the problem would appear to be in the coil circuit of the contactor which powers the starter, rather than in the power circuit itself - I take this from your report that, when the vehicle refuses to start, you hear nothing.  This would suggest that the contactor is not pulling in, and these do make a "clack" when being pulled, one that would be very noticeable if not accompanied by the starting motor not turning.  If you do not hear that contactor, then your starting motor is not being energised anyway, and so can probably be discounted in terms of being the cause of the problem.

It might be that the start contacts within your engine control switch (ignition switch, if you prefer) are becoming oxidised or pitted.  Alternatively, it could be that there is an intermittent or loose connection in the circuit from the start terminal on this switch to the coil terminal, or in a connector along the way, or at the contactor "COMMON" mounting connection to the chassis. (This is generally called "ground" but, as one subject to the influence of electrical codes and utility practices, I tend to reserve the "ground" word for literal connections to "mother Earth"!)

The problem likely will be simple to solve, once found.  At best, cleaning, greasing and tightening connections will suffice.  At worst, you may need to replace the control switch or the contactor.

Good luck ... EGK

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Ernest (Ernie) Kenward

Expertise

The challenges I most enjoy are thoughtful technical questions of a trouble-shooting nature in both electrical, power electronic and mechanical systems, mainly automotive but also machine control and small-machine PLC applications. Please note, however, that I am NOT a walking shop manual! I DO, however, make it a point to have those manuals and other service literature for those vehicles I DO own, and highly recommend that anyone serious about maintenance or modification of their vehicles do the same; MOST of your answers WILL be found there. For that matter, I do NOT go out of my way to acquire shop manuals for any vehicle I do NOT own! That being the case, any general query to me along the lines of "What is the meaning of this code read from the ECU of my 2015 XYZ?" or "Where is the fuse for the windshield washer pump found?" (try your car's electrical distribution panel for a start!) will not go far. What I do offer is a pretty good collection of literature, insights and hands-on experience with 1950s to 1980's Ford products (plus a developing database of information and practice with the Mercedes diesel cars), along with an engineering perspective and the ability to design and implement custom control, electrical and mechanical subsystems for vehicles. For that reason, I am happy to make my thoughts and efforts available to those who are of like mind and/or are seriously making a point of learning about their vehicles. Use the Opportunity to Learn!

Experience

A key skill in my work and hobby pursuits both is STRATEGIC TROUBLESHOOTING. I am a senior instructor in Electrical Engineering Technology at a leading Canadian polytechnic, my areas being Electrical Power and Industrial Control, electrical and electronics design and manufacturing, and AutoCAD and related CAD/CAE software - plus equipment problem-solving and new equipment design and prototyping. Hobby-wise, I have 30-plus years of experience in auto restoration, mostly in electrical and mechanical systems. Ongoing projects include a 1959 Edsel Corsair, my 1978 Ford E250 class-B motorhome conversion, and the care and upkeep of my Mercedes 300CD. My vehicles become engineering test beds for electrical and mechanical upgrades as ideas present themselves. This includes the design and production of circuit boards to restore or enhance features for which no OEM replacement parts are obtainable, or where better specifications or reliability can be had via newer concepts. Regarding the E250 RV conversion, I designed and continue to revise a custom power distribution system, managed by a Programmable Controller (PLC); this has made most revisions as easy as uploading new firmware as I develop it. The "mini" PLC is a powerful device for custom automotive control systems. One good example (there are many) would be the Moeller "Easy Relay"; these offer a wealth of control, monitoring and variable-and-status display options for such projects. A good example project which has worked well is that one for my RV noted above, which has been on the job - revised in firmware only - for a decade now. It is a load management and charging control system to avoid the sulfation-induced early failure that often befalls deep-cycle batteries used in RV power applications. The battery installed in 2003 lasted long enough to more tnan pay for the PLC that contributed to its longer life ... and the PLC will be there for the next battery as well!

Organizations
IEEE - senior member ... past WCC Student Activities; SME - senior member ... past chair, greater Vancouver chapter chair 318; Edsel Owners' Club - have served in various capacities on chapter executive during seventies; have been Power and Driveline resource on the Edsel Owners' Club "E-team" for more than a decade.

Education/Credentials
Graduate of UBC

Awards and Honors
Certificates of appreciation from IEEE and SME for work in student and chapter activities

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