I have a 1996 Ford Explorer (2WD, 4.0L V-6) with approximately 120K miles. The truck has an intermittent starting problem that my local Ford service centers have not been able to diagnose. When the problem occurs, the engine fails to start, even though the starter engages properly. There seems to be an ignition lockout that is setting and preventing the engine from starting. This problem never occurs when the engine is starting cold. It happens in no predictable manner, and intermittently. When it does happen, the vehicle has been run to operating temperature and has set for two to three hours after shutdown. My only attempt at remedying the problem has been to make certain that the plug wires are making secure contact, and by running the transmission lever back-and-forth several times. This does not provide an immediate fix, but after 30 to 45 minutes, the engine eventually starts. The electronics apparently are resetting.

One Ford service center outfitted the vehicle with a “flight computer” to record the engine profile when the problem showed up. However, they could not let me use the recording device for long enough for the problem to occur, so this was just a waste of time and money.

Has this problem exhibited in other 1996 Explorers? Is there a test sequence that enables diagnosis of the failed component(s)? If not, is there a means of over-riding the starter lockouts so that the vehicle may be reliably started?

Your help will be greatly appreciated.

 

A friend of mine had a similar problem with a 95(?) ranger. Several expensive trips to the local Ford Dealership, and to independent mechanics, but he could never reproduce the problem. They couldn't find any codes in the computer, or seem to locate any other problem. Then one day, in a foul mood he lifted the hood and started hitting things when it wouldn't start, he hit a black box, and whirrr...the fuel pump kicked on. Well...his problem wasn't solved but finally he new how to start it. Several months of this, the problem was infrequent, and he finally took it to the dealer. The checked everything in the box (some sort of power distribution box) and found a faulty ground. After fixing it, the problem never appeared again. I'm not sure if you can hear your fuel pump initialize when you turn the key to on, without starting it, but if you can't maybe this will give you some ideas.

 

I had a similar problem on my 92 Explorer. It would start fine and run great, then you would shut it off and it wouldn't start for at least an hour, sometimes more. It was also draining the battery on a regular basis. I also started hitting things under the hood and when I banged on the Power Distribution Box (where all the big fuses and relays are), it would start right up. I pulled all the fuses one night and started replacing them one by one. I found out the problem was in the fuel pump circuit. I replaced the fuel pump relay ($7 at your Ford dealer) and the problem has gone away completely. Check and see if you hear a whirring sound when you turn the key to the On position. That is the fuel pump creating pressure in the fuel rail to start the truck. Start the truck and let it run for a bit. Then shut it off and perform this test. When you shut it off, get out of the car like you normally do, but listen carefully. The fuel pump should run no more than 1 - 2 seconds before shutting off. If you can open the door and get a foot on the ground before the pump shuts off, then your relay is probably bad. I did this test and it worked for me. Just something you might want to check...