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Hi guys, new to forum here! A few months ago after not having started my EXPY for a week, I went out to start it and it just clicked. It would not do anything other than click when the cables were hooked up to jump it. It took about 5 minutes of charging when we jumped it off of another vehicle to get it to turn over. It then started with no other problems until this morning(Monday morning). It had been parked since Friday evening. My wife tried to start it and it just clicked, and we jumped it with the same results as stated earlier. I took it to the local auto parts store and tested it and the tester said everything was normal.
Have you had any rain recently. My 2000 Expy did the same thing a couple of weeks ago. Seems that the windshields develop a leak and drips water on the GEM module. This causes all kinds of electrical things to pop up, like the heater fan to come on in the middle of the night and drain the battery down. Just a thought.
Hey, don't know if you figured out your problem or not yet, but I had the same problem. I was cleaning it out, listening to the radio one night, and then went to bed when I was done. The next morning, it just clicked when I tried to start it. I jumped it, and it was fine til I turned off the ignition, then I couldn't start it again. I took the battery in the A-Zone, and they said it was fine. I took the battery then to Advanced Auto, and they too said it was fine. So, I went to Wal-Mart and bought a new battery just to compare, and now no more problems.
More than likely, you were experiencing oxidation on the positive battery terminal. I had this happen all the time on my '93 Exploder. About every 3-4 months I would have to clean off the deposits on the battery terminals (the positive was always the worst). Finally, a mechanic who sold me the Interstate battery recommended putting conductive grease on the terminals.
I used some regular joint grease, and never had a problem again for 3 1/2 years.
Drug the Exploder to the dealer last week and got a 2000 F-150 XLT -- AHHHH what a feeling to be back in a truck!