Well, I no more than finish putting on new tires and replacing the A/C unit and it looks like she now has a starter issue! Hooked everything up after replacing the a/c system and she fired up with cool air blowing! The next morning my wife told me she (the expy) was dead and would not start. All the lights/accessoried will come on but she won't turn over. I pulled the solenoid (relay) up on the firewall just to be sure and that did not help. So I am guessing it has to be either a locked up engine (impossible since it was fine last night) or that the starter is out. Does this sound correct to everyone? I "beat" on the starter with a hammer and it did not help either.

If I am on the right road, I can't quite figure out how to pull the starter on this truck. Any ideas??? It's the 5.4L and I was able to locate the battery cable and disconnect from the starter and then I found the one mounting bolt right next to that. There seems to be one more bolt on top that I can feel where the starter connects to the bell housing. The six inch socket extension is too long with the 1/2" deep socket on and too short with a regular socket.

I know this will be simple once I get the starter off and sure don't want to pay the stealership $$$$$$$ for something I should be able to do in half an hour. As always, thanks for y'alls help.

 

I forgot (assumed) everyone would know that I have already checked the battery and it is good, the connections are tight, the relay (solenoid) is clicking and we even tried to jump start it just for grins. Nothing worked.

 

Your starter is more than likely good and why it will not start is the spade terminal wire is bad where it plugs into the Solenoid on the starter. Just cut back about an inch of the small wire and crimp on a new spade terminal.

Here is a diagram:

 

thanks for the reply subford. i am in no way disputing your advice because i will be greatly relievd if that's all it is. but why would you think it is not the starter? also, i wander if you could please verify on the wiring to the starter relay up on the firewall. as it is now, there is a black wire and red wire attaching to the bottom terminal of the relay, an orange wire that plugs in on the right side and then the u shaped wire harness is attached is as it is supposed to be, coming in from the left to the top and bottom terminal.
if you are correct about this i will be so very happy!!! going to go check it right now. thanks for the post.

 

The starter may be bad but the spade connector is a vary common problem in Fords with this type of starter. The heat from the exhaust manifold is the main cause of this problem. Some have reported that Ford does have a fix for this and no longer use the spade terminal.

I do not have a wiring diagram and I am not familiar with the wiring on a 98 Expy but I think this is the type of starter you have.

 

well, thanks for the advice. i tried the suggestion, crossed my fingers and hoped for the best.......turned the key and she's still dead. so........back to trying to figure out how in the world to get the stupid thing off. this is yet one more time i'd like to find some of those ford engineers..................
thanks for your suggestion.

 

Here are the instructions for a 99 Expedition. I do not see anything special. I think on some of the Explorers you have to take the inner fender loose.

WARNING:
When carrying out maintenance on the starting system be aware that heavy gauge leads are connected directly to the battery. Make sure protective caps are in place when maintenance is complete. Failure to follow these instructions may result in personal injury.

1. Disconnect the battery ground cable (14301).

2. WARNING:
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

Raise and support the vehicle; refer to «Section 100-02».

3. Remove the starter motor solenoid terminal cover (11N087).

4. Disconnect the starter motor electrical connections.

1 Remove the two nuts.

2 Remove the battery cable.

3 Remove the starter solenoid wire.

5. Remove the nut and the starter motor ground cable.

6. Remove the three bolts and the starter motor.