1995 E150 5.8L-E4OD-188K miles. About 2weeks ago it started just clicking when key was turned. It would eventually catch and start after a few key turns. Checked battery terminals and cleaned them. Tested battery with multi-meter and it was 12.4V and 14.3V when running. This morning it started clicking again but didn't catch after a dozen key cycles. I then did the screwdriver trick at the starter relay posts and it sparked/clicked a few times and then caught and started. Is this a connection problem at the battery or maybe the starter relay? Any thoughts? Thanks.

 

Sound like you need to cut off about an inch of the small wire at the starter and crimp on a new spade connector.

Here is a diagram.

 

Your problem sounds like it is at the starter, since you did the screwdriver trick. I would try subford's idea or replace the starter if that doesn't fix it.

 

With the starter on the passengers side of the 5.8L engine would it be more accessable to check the starter connections from inside the cab by removing the doghouse (engine cowling) or from under the van? I can do it either way but I'm at the in-laws and they have an inclined driveway and I just don't like raising it up and crawling under it even on jackstands. I guess if I can access the starter from above at least I can check the wiring connections. I do think that if I have to replace the starter, say, it is better accessed from below. I have no knowledge of the maint. history of this '95 hi-top conversion van save the last two years and my GF doesn't know what her ex had done or not done with it. I'm slowly discovering that its 10-11 year old parts have a way of giving out at nearly the same time too! In the past year these componets have gone bad: Trans-cooler hoses and clamps, trans-pan gasket, one trans-pan bolt heli-coiled, fuel filter, new plugs/ wires/cap/rotor, rear heater coolant lines, front heater core, IAC valve, radiator, pads and rotors (twice), front wheel bearings, set of tires and one alloy wheel leaking. And various other small things like trim falling off. At this rate I'll have everything replaced soon! Thanks for your replies and I will post back results.






Thanks for the fast replies.

 

If you just need to move it to some where else you might get by with just wiggling the small red wire where it goes on the starter.
You may be able to do this from inside if you are good at working on something you can not see.

 

10 years does seem to be when serious stuff will start failing. But you will find it will come in waves. Get through this round of repairs and in my experience the problems will go away for a few years, and then you will have another round of problems later on.

 

Well,
I started with testing at the battery. 12V engine off and 14.3V engine on. Cleaned both negative and positive post and clamps on battery. Cleaned ground for small wire coming off negative post. Crawled under the van and inspected starter and solinoid connections. Solinoid connection seemed loosely connected. Wiggled the solinoid connection and seated it firmly. Now it starts normally.....for now. I'm sure it was the small wire on the solinoid. Thanks to all for the response!