Notices
6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Intermittent start (basically no start)

Thread Tools
 
Search this Thread
 
Old Sep 7, 2019 | 11:08 PM
  #1  
USAF_POL's Avatar
USAF_POL
Thread Starter
|
Junior User
Joined: Aug 2013
Posts: 58
Likes: 0
Intermittent start (basically no start)

2003 6.0 PSD Excursion. Installed Flex-a-Lite fans, Leece-Neville AVi160T2002 / 230 Amp alternator and FICMRepair set of upgraded battery/alternator connecting cables. Now I have this issue; it starts every now and then. The first time this happened (less than 24 hours after install and maybe 6 starts) I thought it was the starter so I swapped in a starter from a 6.7 (it was readily available) and it came back about 6 starts later. I even unplugged the fans from the ignition on fuse thinking that might be the issue but still no start.

I have attached a video of what it is doing. A couple of times it has cranked over for almost a second but in this clip it wouldn't do that for me.

Any thoughts of how to diagnose? Thanks in advance for you time.

 
Reply
Old Sep 8, 2019 | 02:58 AM
  #2  
IHateCommieCars's Avatar
IHateCommieCars
Logistics Pro
10 Year Member
Liked
Loved
Community Favorite
Joined: Jul 2014
Posts: 4,673
Likes: 532
From: Houston, Texas
Have you tried taking the belt off just to make sure the AC or something isn't locked up?
 
Reply
Old Sep 8, 2019 | 10:32 AM
  #3  
USAF_POL's Avatar
USAF_POL
Thread Starter
|
Junior User
Joined: Aug 2013
Posts: 58
Likes: 0
Originally Posted by IHateCommieCars
Have you tried taking the belt off just to make sure the AC or something isn't locked up?
Didn't think of that, just did and same results, no start/crank over. Just what you see in the video.
 
Reply
Old Sep 8, 2019 | 10:58 AM
  #4  
bismic's Avatar
bismic
Fleet Owner
Community Builder
Liked
Loved
Community Favorite
Joined: Nov 2003
Posts: 27,918
Likes: 3,636
Club FTE Gold Member
Sounds like bad batteries or wiring issue to me.
 
Reply
Old Sep 8, 2019 | 12:38 PM
  #5  
SmackDaddy's Avatar
SmackDaddy
Postmaster
Joined: Sep 2016
Posts: 3,941
Likes: 240
From: Texas
Man there are a lot of these threads here lately!
I agree, it sounds like a voltage issue. First things first, are your batteries good? Charged? Better figure that out before you burn up the FICM.
 
Reply
Old Sep 8, 2019 | 01:07 PM
  #6  
USAF_POL's Avatar
USAF_POL
Thread Starter
|
Junior User
Joined: Aug 2013
Posts: 58
Likes: 0
Originally Posted by bismic
Sounds like bad batteries or wiring issue to me.
Originally Posted by SmackDaddy
Man there are a lot of these threads here lately!
I agree, it sounds like a voltage issue. First things first, are your batteries good? Charged? Better figure that out before you burn up the FICM.
This issue popped up with old batteries after the new installed parts. I now have new batteries but it's possible I got a bad set. Just realized when I left my back pack in the Walmart parking lot my DMM was in there so I get to buy a new one. I checked the voltage with my OBD port SGII and it was spring below 12 volts, when I get the chance I'll put a charger on it after buying a new DMM and wait until they are charged and try again.

When my wife was driving it and it wouldn't start the last time she drove about a mile to the store and when she tried to leave it wouldn't start. I'll be surprised/disappointed if it's the brand new batteries. The nearest pepboys is an hour away. That's where they are warrantied. We bought them when we lived by one and now we don't.
 
Reply
Old Sep 8, 2019 | 06:20 PM
  #7  
xcrsp440's Avatar
xcrsp440
Fleet Mechanic
5 Year Member
Liked
Joined: Nov 2016
Posts: 1,343
Likes: 94
Perhaps not the batteries, is your alternator recharging them?
 
Reply
Old Sep 8, 2019 | 10:55 PM
  #8  
USAF_POL's Avatar
USAF_POL
Thread Starter
|
Junior User
Joined: Aug 2013
Posts: 58
Likes: 0
Originally Posted by xcrsp440
Perhaps not the batteries, is your alternator recharging them?
It better be! it is brand new from FICMRepair, less than 20 miles of use, maybe an hour total... lol. It is a Leece 230 amp.

After talking with a local mechanic I am going to go thru all the connections I made and clean every surface and put some battery protectant spray on them, charge the batteries again and try it... If that doesn't do it I am lost. Well, currently lost so either way.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Fords at 2026 Carlisle Ford Nationals

 Joe Kucinski
story-1

3 Best / 3 Worst Parts of Modern Ford Ownership

 Brett Foote
story-2

10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

 Pouria Savadkouei
story-3

Every 2026 Ford Engine Explained

 Brett Foote
story-4

10 Ugly Ford Trucks That We Still Kinda Love

 Joe Kucinski
story-5

10 Things Every Truck Owner NEEDS (2026 Edition)

 Michael S. Palmer
story-6

Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

 Verdad Gallardo
story-7

Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

 Joe Kucinski
story-8

2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

 Brett Foote
story-9

Top 10 Ford Truck Tragedies

 Joe Kucinski
Old Sep 9, 2019 | 06:08 AM
  #9  
bismic's Avatar
bismic
Fleet Owner
Community Builder
Liked
Loved
Community Favorite
Joined: Nov 2003
Posts: 27,918
Likes: 3,636
Club FTE Gold Member
You can't just measure battery voltage and call them good. They need to individually be load tested.
 
Reply
Old Sep 9, 2019 | 08:42 AM
  #10  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,832
Likes: 3,119
From: Jersey Shore
Take pictures of all the cable connections at the batteries and the starter and post them here..
 
Reply
Old Sep 9, 2019 | 09:47 AM
  #11  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,832
Likes: 3,119
From: Jersey Shore
You might also want to try rotating the motor by hand off the crank pulley (with a breaker bar) to see if you have a hydrolocked motor.
 
Reply
Old Sep 9, 2019 | 03:15 PM
  #12  
IHateCommieCars's Avatar
IHateCommieCars
Logistics Pro
10 Year Member
Liked
Loved
Community Favorite
Joined: Jul 2014
Posts: 4,673
Likes: 532
From: Houston, Texas
Not sure if this could cause it, but easy test - swap your relays around. Maybe the one powering the starter is failing.
 
Reply
Old Sep 9, 2019 | 03:38 PM
  #13  
Striderwv's Avatar
Striderwv
More Turbo
Joined: Apr 2007
Posts: 695
Likes: 78
From: Almost Heaven
I always charge new batteries before using them. Not sure, but it sounds like you did not. Also, did you test to make sure you had at least 12.6 volts before you started with your new altenator? And did you get between 13.8 and 15.0 volts at idle withing 3 minutes of startup. If you got votages lower than these in either case, you need to recharge the batteries and recheck, double check cables are good and making good connection, and make sure your belt is not slipping. Previous is all from Ed's instructions. Bear in mind the alternator is not a charger. I recently put a new one in and I passed all of Ed's instructions, but I did notice it took a few short trips before my battery tender was not charging an extended time (I plug it in every time I park). I,m not sure how long your trips were. I would hope the new batteries are ok, but you never know. Like Mark said, a load test is the only way to know.
 
Reply
Old Sep 10, 2019 | 01:15 PM
  #14  
USAF_POL's Avatar
USAF_POL
Thread Starter
|
Junior User
Joined: Aug 2013
Posts: 58
Likes: 0
Ok, found out something interesting... After removing all "aftermarket" cables and cleaning and trying still nothing. I had just about gave up. Put it all back together, ensuring everything was tight. Stood in the driveway with my favorite cold one, pushed the remote start and.... It started. Tried it a couple times and no problem. Got in it with the key, tried starting and nothing. Went into the house and grabbed spare set, nothing. Used remote start and fired right up... Thoughts? Lol

PS. I think my ignition decided to **** the bed the day after the install and it created a headache trying diagnose new work when one possibly has nothing to do with the other.
 
Reply
Old Sep 10, 2019 | 05:56 PM
  #15  
Striderwv's Avatar
Striderwv
More Turbo
Joined: Apr 2007
Posts: 695
Likes: 78
From: Almost Heaven
Now I know why I never installed a remote start. Or was it the manual transmission? Glad you figured it out. Good case for posting all modifications.
 
Reply



All times are GMT -5. The time now is 08:19 AM.

story-0
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-1
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-2
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-3
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-4
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-5
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-6
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-7
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-8
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE
story-9
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE