I have a 2003 7.3L excursion, that has left me stranded twice now. It periodically decides not to crank. I can start it in the morning drive to work, try to start it about an hour later and no start crank. Everytime this has happened the truck has full power, all lights and accessories work, fuel pump kicks on, even when I turn the key everything still have power, the light don't dim. I did notice when I hold the key down the odometer goes blank and if I hold the key down for longer then 5-10 seconds the air bag light starts blinking, this might be irrelevant to my problem but I thought I would mention it.

In the past when it hasn't cranked, I have removed all four terminals and cleaned them and it usually would start. Yesterday was not the case, it just wouldn't crank, I even recleaned the terminals. they batteries tested good. I tried jumping the starter but it wouldn't. I installed a new solenoid on the starter and it fired right up first crank. I restarted it three times last night it cranked and fire all three times. I did notice that I had to hold the key in the crank position longer than normal before the start would crank, about 3-5 second delay. the delay has been present before from time to time.

This morning the problem has come back, again full power, no crank. I have tried shifting it to neutral with no change. Does nyone have a clue what this could be? I am sure there are many possibilites. I have read the neutral safety switch could be out of adjustment, which I will look at today.

Where is the starter relay on this truck? Also there is a start solenoid looking thing next to my fuel bowl, does that have anything to do with the starting system?

 

I had this problem with a 99 expedition several years ago, after doing some internet searches I found that the expedition had a switch or solenoid on the firewall that was going out. I think it is called a starter solenoid. I replaced the unit and never had the problem again. I don't know if the excursion has the same thing but it was a $15 fix at the time.

 

what did it look like? On the Excursion the solenoid is part of the starter, which I replaced yesterday. Was it maybe a relay? I think those are mounted on the firewall somwhere.

 

Hello,

Not a mechanic but, a bad ignition switch can produce the same symptons mentioned. Next time it happens, whip out the DMM (digital multi meter) and check your voltage at the starter.

 

I can't remember the part name, but it was on the firewall and not the typical solenoid on top of the starter. It wasn't a relay either. I actually found the answer in this site from a google search. It was the first time I used this site.

 

I decided to swap starters, I had another starter that I know works so I put that one in. Before connecting the two cables to the solenoid I checked the voltages. Both readings were equal to the batteries. Once the starter was hooked up, I tried to turn it over and nothing. All I would get is a click down at the starter. We hooked up some jumper cables still nothing. I tried it a few more times and it cranked and started. I shut it down after a minute, tried it again and nothing. This is so frustrating!

 

Sure sounds like a bad ignition switch to me. I dont know how the excursion is set up but on the Thunderbird I had, it was a two part plastic sandwich type switch. The two halves would separate and you would have to either turn the key super fast, or turn it really hard to crank it. It got worse to the point it wouldnt crank at all.

 

So the starter only clicks when you try to crank it? That tells me bad solenoid. Apply B+ to the solenoid terminal to make sure it's good. It should crank then. The relay is in the fuse box. You should hear it click when you try to crank it.

 

Shepherd the relay clicks when trying to start it. I swapped the ignition switch this morning with no change.

 

Is the lead from the solenoid to the starter corroded? On our trucks we have this every now and then from the salt. The solenoid will click but the current won't flow from the solenoid to the starter even though it only 1" away. Have to make absolutely sure every connection on the starter is pulled apart and cleaned very well with a wire brush, file, or grinding stone. After all clean a complete covering of dielectric grease will keep it from getting corroded again in a short time.

 

They appear to be clean, with no corrosion. I checked the voltage at at the starter and the readings were ok.

 

You checked the voltage at the starter while someone was turning the key to start and there was power on the starter side of the solenoid?

The short wire you see in the pic below. Its connection to the solenoid has to be clean.

 

edit.......

Nevermind...speed reading got me again

 

Thanks to all that replied.

Today I could here a click coming from the starter, and all the voltages again checked out. I removed the starter and we bench tested it and the starter just didn't have power. After first the bendix wouldn't engage, and it wouldn't spin with power. I went to my local starter shop, not the chain parts stores and got a new starter.

Again thanks to this website and all the great members.

 

I was gonna ask you were absolutely sure the one you swapped in was good.

But like my first post above, nevermind!

Stewart