I'm out of ideas, so I'm hoping to get some here. My Excursion won't turn over. Drove to the store and came back out, all the dash lights come on as normal, turn the key and nothing happened. Played with the gear selector, cycled the key a few times and finally got it to start. Drove it home, turned it off, and 30 minutes later it wouldn't turn over again. Everything powers up, but starter won't turn.

Replaced the nuetral safety switch and turned the key on and it turned over very slowly and then I got dash clicking noises. Had the batteries tested and they failed. Bought 2 new batteries and also a new starter for good measure. Cleaned the battery connections at the battery, installed the new batteries and the new starter and she fired right up. New starter turned the engine over really fast.

Drove it around the block for a few minutes and then parked it in the garage. Came out an hour later, back to no turning over.

In summary: new batteries, new starter, new nuetral safety switch, swapped dash relays, no luck.

I have 12.38 Volts at the starter battery post, and when I turn the key, I get 11.7V at the switched post on the starter. I am out of ideas. Keep in mind, the 2002 does not have a solenoid on the fender.

 

Moved to the 7.3L PSD forum.

Stewart

 

This sounds like a loose ground. Check your battery grounds first, then the grounds at the underhood fuse box. I think there is four of them. Then there is two grounds on the firewall beside the master cylinder. If this does not solve it, there is several under the dash, look carefully at the two that runs into one connector tapped into the steel dash support. These are for the pcm. That is all I can think of.

 

Where did you get the starter from? I replaced my starter 2002 f350 with a new starter from napa. There was a big red tag which I did not read on the starter solenoid which stated "do not torque over 10 IN LBS), I could be wrong on the torque. But anyway, I just tightened with my socket and I did not realize I broke the solenoid. When I took the wire off the solenoid, it was obvious. Remove the large wire from your solenoid and see if the bolt is loose. If it is, that is most likely your problem. Here in Wyoming, neither NAPA nor Ford dealership would sell you the solenoid only, they wanted to sell you the entire starter but I found that you could buy the solenoid only from any workshop that rebuilds starters.

 

One other note, if your batts are reading that voltage, your alternator is getting a little weak. It should read 13+. Loose grounds will cause lower voltage also. I do not know what version of 7.3 you have, but also look at the grounds around the solonoids on the top of the block.

 

If the glow plugs are on, I only see about 11.7 volts.

 

11.7 is enough to start. It will not even think about starting if it drops to 10.

 

Lead acid batteries should be about 2.1 volts per cell when fully charged. A 12v battery would actually be 12.6v.

 

when your starter refuses to turn engine over,try checking for power [ voltage ] on the start [ s ] terminal post on your starter solinoid, this way you can trouble shoot from starter all the way back to batteries on test at a time.

 

Is there a bosch type relay in the fuel box for start on an 02?

 

Played with the gear selector and it started? Have you tried shifting to neutral when this problem happens and attempting to start?