I have a '99 E350 with the V-10 engine with 225K miles on it. I recently went into the shop for a couple of things - one COP was flaking out, a front ABS sensor replaced as well.

It ran well as expected - shop is reputable. This is not may daily driver so it sat for a month or so. I went to start it yesterday and the battery was flat. It didn't start when I jumped it - turned the key on and it made a rapid ratcheting sound so I pulled the battery and went to a local place (fleet farm) where they tested it. 50% charge - 12.2V but the battery was OK.

I charged the battery more and got it to start - gassed it up, washed it, ran it around, and parked it. Tried to start it again and got the same issue - but battery was up to 12.6V (open circuit without engine running).

OK - starter? Pulled the starter and took it down to local Oreilly's and checked out OK.

Starter relay - replaced, same result.

In addition the last time, all the power circuits went dead when I turned the key on to start the engine. The power was on as the courtesy lights, dash gauges, etc. came on before putting the key into the start position. I pulled ulled the battery and relay again to see if I let any magic smoke out - none observed. Checked all the fuses in the fuse box in the engine compartment - all checked out as good.

Reinstalled the battery and starter relay. All the circuits came back on. Lights, turn signals, console gauges, radio, courtesy lights, etc.... Then I turned the blower on to high and everything went dead. Nothing came back on.

It is as if there is a overload circuit that blows and is self resetting when a high load is turned on like the blower or the starter.

What gives? I have no manual for the van so I am shooting in the dark.

What do I check next???? Any help is kindly accepted.

 

check the ground wire

 

I agree with checking the ground.

 

Might be a silly suggestion but, did you clean the battery terminals? That's where I would start if you haven't.

 

From what you wrote on the problem, it seams every time you disconnect the battery cable, or move the cables, the problem exists or goes away, that points to a problem with the battery cables.

A quick test is to have the dome light on, turn the key to start, if the dome light goes out, or becomes very dim, there is a problem with the cables, connection to the battery, the high amp draw for the starter shorts out the little current coming from the cables.

I'm sure this year used the lead crimped on battery connectors.
Good chance the cable is corroded inside the connector, causing the problem.
Plus, the van is nearly 20 years old, and age don't help with copper corrosion.

Best to cut off the old lead connector, look at the cable and if the copper has turn very black, that's corrosion.

You could replace the cables them self with new, or use this item to strip back to clean copper cable and replace just the ends.



Replacing both the positive and negative cable ends will solve many problems, as power connection will be restored to the sensors, the alternator will be charging the battery properly again.

 

Guys - you both nailed it! Negative battery had battery clamp replaces and was corroded. Cleaned it up and it srarted up like it should. Thanks!

 

I worked in the battery shop while I was going through auto tech.
90% of the starting problems were dirty terminals.