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Hi, I bought a '92 Explorer XLT in April. Last week I got in it and once I turned the key, all the lights come on, radio, etc. but nothing else. I can hear the gas pump go for a few seconds but that's it. The engine doesn't even try to crank. The battery reads at 12 volts but the post were corroded then cleaned well. Still no go. We then replaced the entire positive cable thinking the corrosion may have continued in the cable. No go. We then replaced the starter relay and the engine started. Yes! Five minutes later we tried the engine again and we are back to square one. We also reset and reset the inertia switch but still no results. Any ideas?
The starter solenoid is interlocked by the safety switch on the transmission. If automatic, try moving the sift lever around while the key is in the start position. If you connect the little post of the fender starter solenoid to the + terminal, you can manually start it. You either need an new switch on the transmission or the connector may be corroded. Some have just wired a push button on the dash cause they don't want to spens any money on a 92. Great caution must be used because it will be able to start in drive.
Another potential issue is the ignition switch. I had to replace the switch in my '92 around 2 years ago. It's located down on the sterring column and not difficult to change. I believe it was around $12 at he parts store. Also, as OHW noted, there are safety interlocks to the transmission. He covered the AOD, but if it's a manual transmission, I suspect there is a limit switch on the clutch linkage somewhere. If it passes the relay test OHW mentioned, it could be the transmission safety interlock, or it could be the igition switch, or it could be the wiring in between them.
Crank sensor has nothing to do with engine cranking. Is it automatic or manual? As others have stated, may be clutch interlock, neutral safety, or ignition switches.
I have had similar problems. Most likely the starter is bad. When you have a car that old it is not surprising. I own a 92 and have had to replace mine once . I consider myself lucky. It is a very simple thing with explorer as there is a lot of room. Only two bolts or nuts to work with. Well three if you count the starter wire. Suggest cleaning with a spray first. Really an easy job compared to most vehicles. Do it with the engine cold. Make sure to disconnect the battery first. Take it to an auto parts store (chain) and they will test it. Replacing is easier as it is clean.
One other thing to check is the ground battery cable connection at the engine block. (It may be on a starter bolt.) Remove the cable end, clean the area with a wire brush, and retighten.
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