Just bought an 04 F150 reg cab 8' bed xlt 5.4l 4x4. This truck is replacing a 99 f150-lariat 4x4.
Love the truck, got a good deal, like the saleman, like the dealer. The first morning I go out to start the truck to warm it up. It's 4 degrees out. Stick in the key and turn it. Nothing but clicking of relays. Oh no did I leave the lights on? Nope. Maybe it's the keys, run back in house get other set of keys. Did I mention it's 4 degrees out. Try the other set, same thing. Pop the hood and look at the battery connections. Accidently hit the panic button on the keyfob. Strong horn, flashing lights. Get back in and try again starts fine. Maybe it's the security system. Next day starts fine. No problem. Next day same thing no cranking. Lock and unlock the doors. Press the panic button, it cranks and starts. Call the dealer they say bring it in and they check for error codes. Find nothing. Next day starts fine. Next day after that will not crank. The dealer had told me to look at the red dash light, if it flashes it is a key problem. Turn key no flashing light. Open door and listen as I turn key. Hear the distinctive sound of starter gear pinking on ring gear. Click the key a couple of times and then it starts. Ok it's the starter. Call the dealer and ask to speak to the service manager who looked at the truck previously. Sorry he doesn't work here anymore. Get the assistant service manager, have to start a ground zero explaining the problem. Bring it in and we'll look at it. No I say replace the starter. The truck is going in on Thursday. It will be interesting to see what happens. My question is why? Is this a quality thing? This is a tough one to admit to other truck owners. The Chevy and Dodge guys are laughing there asses off.

 

Stick to your guns and make them replace the starter. Sometimes they just flake out. Could be the starting capacitor, could be the starter itself, who knows.

I once had a replacement starter for my car refuse to work even through it was new (rebuilt).

 

I had a similar problem with my 97 XLT a few months ago. I was thinking about getting a new starter...but decided to check the connections on the old starter first. I was able to get about a half turn on each connection without trying very hard. All my starting problems went away immediately !!!!!

 

Gears not meshing, could be as simple as starter not tight or flexplate bent. If they put it up and really look, they will see the problem. Being new is the time this will happen,it has happened to every make of auto ever made.Just for s and giggles,throw a wrench on the starter bolts, see if they are tight, I know,I know it's 4deg and laying on the ground for a min is no fun, just do it for your own piece of mind.