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We have a 94 ford explorer and every now and again it has issues on the start up. It will sound like it will want to crank over but just won't. If we wait 20 mins it will start up no problem. We have changed the fuel pump, fuel filter, ignition coil, and fuel pump relay but it still has this problem. Also occasionally the a/c blower wont turn on. Tonight it happened again and I pulled the fuel pump relay out and it was really hot, after it cooled down and was put back in the car started. I am beginning to think it maybe an overheating issue that is affecting the relays but am not sure. I was also wondering about changing out the relay box, but before I spend more money thought I would ask if anyone else has ever had a problem like this. Any advice would be helpful.
For clarification, generally "cranking" is referred to as what the starter motor does when engaged. So when you say, "sound like it will want to crank over but just won't" I want to understand better if the starter motor spins the engine over it just won't "fire" and start, or if the starter motor doesn't even spin the engine over.
The motor turns it just won't fire. When we put ether in that will catch and then quickly give out. We knew that the engine was not getting fuel which is why we replaced the things we did, but unfortunitly it still keeps happening now and again.
Okay, and the hot fuel pump relay is an interesting find. If something is causing that relay to open and close rapidly, or if the switched contacts are making an intermittent connection, that could explain the heat. I'd suggest you carefully inspect the contacts in the fuse/relay box to see if they show signs of arcing (carbon black, clean rough areas, etc.). If so, you will want to replace or repair those connections before reinstalling the relay. The fuel pump relay is likely also the same as one of the other relays. You could try swapping relays (pick one that is less critical, such as maybe fog lights or something) if you confirm the connections are good. And finally, a test light in the coil trigger when the truck won't start will help you determine if you have a relay coil request at the time the truck won't start - maybe an ignition switch issue.
My 02 Sport Track with 4.0 had the same problem. About once a month or so the engine would turn over but wouldn't "fire up". Then sometimes a minute later or so, it would then fire up. The engine normally ran great: but, I would never know when this start problem might happen.
I brought it to the Ford dealer and left it there until the problem happened again and they got the error code. The problem was a $15 dollar rubber vaccume hose. They said the line had something to do with the air to fuel regulation. This caused a starting problem. Then after the truck sat for a bit the air fuel would balance out and it would start right up.
My hose was stretched and came off. They put a new one on attached with a small hose clamp. To find the hose look under the hood on the passanger side. It is on the top near the fire wall.
A similar problem happend a year earlier when another vaccum hose near the altenator got a crack in it. My truck had a very rough idle and would nearly die when the truck came to a stop. I hope this helps someone.
I,too am having the same problem with my 97 ford explorer but mine is suspected to be the cam sensor.Does anybody know cam position sensor position to the pick up wheel? I spray carb cleaner on the sensor and it starts.