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'91 Aerostar Won't Start

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Old Jul 27, 2006 | 08:02 PM
  #1  
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'91 Aerostar Won't Start

I'm getting really frustrated with this, it seems to be an ongoing problem. About 3 weeks ago, I got in and it wouldn't turn over. I replaced the starter solenoid and that seemed to fix it. This morning, I was out shopping, got in and it wouldn't turn over. You turn the key and lose all power. I wiggled the wires around and kicked it a couple times and got it started and then got it home. The next time I got in it, same thing, but nothing I did would get it to go. So I took back the solenoid and replaced it, still nothing. Battery is fine, starter is fine, so far as I can tell, all the cables are fine, nothing looks bad. Is there something I'm overlooking? When you turn the key, you either get nothing at all, all the dash lights go out and it's completely dead, or you get a bunch of clicks from all over the engine before the whole system goes dead.
 
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Old Jul 27, 2006 | 09:31 PM
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Cephus:

Somebody here was just going through that same clicks here a few months ago.

I could be wrong but I believe that he took loose and cleaned the two big black connectors on the firewall and that fixed it.
(I Think)

Or I would look for a bad ground.

JaY
 
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Old Jul 27, 2006 | 09:35 PM
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Sounds to me like a bad connection at the battery. Check the batt terminals. Pull the cables clean and reinstall. Also battery could have an internal open. Next time it does it turn on the headlights make sure they are not on. Take a screw driver and touch the battery terminal to the battery cable to see if you are loosing connection. Kinda wedge it in there..
Cables can go bad internally also.


Dick
 
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Old Jul 28, 2006 | 12:20 AM
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The easiet war to find a source of problem is to ask someone to try to start engine and measure voltages on terminals, wires, relay to find voltage loss with AVO-meter
 
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Old Jul 28, 2006 | 10:45 AM
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Your cables my look clean on the outside, but be bad on the inside. I would replace them and clean the mountint point where the ground hooks up.
 
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Old Jul 28, 2006 | 11:32 AM
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I'll go ahead and replace the cables and see if that helps. Now that I think about it, I was thinking that the positive cable felt a little "crinkly" for lack of a better word so there might be an internal short. I'll keep my fingers crossed and hope that's all it is.
 
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Old Jul 29, 2006 | 12:48 AM
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Mine did that a few times. It turned out to be corrosion on the battery terminals. The looked fine on the outside but had enough crud to make it stop working once in a while.

gumboot
 
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Old Aug 5, 2006 | 06:49 PM
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Well, still no go. I replaced the cables, replaced the starter solenoid again, checked the starter, had the battery tested, everything is good. I'm thinking it's probably the ignition switch so I went to start taking the steering column apart and I can't, for the life of me, get the damn wheel off. I'm cranking so hard on the gear puller I'm afraid I'm going to twist the column off and it's just not budging. There isn't some trick to taking the wheel off on an Aerostar is there? Every other car I've pulled, it popped right off, this one just won't move at all. I've got lubricant on it right now and hopefully that will help, I don't know that this wheel has come off since the van was new.

What else can I be missing?
 
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Old Aug 5, 2006 | 07:08 PM
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You should try to jump the solenoid out to see if you get the starter to turn over. At least then you will have a clue as to whats going on. Take a wire and go from batt positive to the small solenoid wire that energizes it. The starter should turn. Then you will know that the wires are good for carrying high current..Take a test light and see if you get power with the key at the same terminal. Thw wheel shouldn't have to come off to get at the sw does it?

Dick
 
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Old Aug 5, 2006 | 07:17 PM
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Originally Posted by 99f350sd
You should try to jump the solenoid out to see if you get the starter to turn over. At least then you will have a clue as to whats going on. Take a wire and go from batt positive to the small solenoid wire that energizes it. The starter should turn. Then you will know that the wires are good for carrying high current..Take a test light and see if you get power with the key at the same terminal. Thw wheel shouldn't have to come off to get at the sw does it?
It's not 100% necessary but it's a lot easier, otherwise the only access you have is through a tiny opening, laying under the steering column. The mixture of a little ingenuity and a lot of lubricant got the wheel off anyhow. Now I'm wondering if there's some way to test the ignition switch rather than just replacing a $110 part and keeping my fingers crossed.

On the solenoid, there are three attachments, one for the battery negative, one for the battery positive and one for a small booted wire on a small terminal, is that the one you're talking about? Just jumping from the positive to that terminal is going to get the engine turning (or started)?
 
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Old Aug 5, 2006 | 07:20 PM
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Turning unless you have the key on..Then it might start...Do you have solid lites on the dash now..

Dick
 
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Old Aug 5, 2006 | 07:34 PM
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Make sure its in park!!!
 
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Old Aug 5, 2006 | 08:06 PM
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Originally Posted by 99f350sd
Turning unless you have the key on..Then it might start...Do you have solid lites on the dash now..
What happens is that when you turn the key to accessory, you have full lights, everything works fine. The second you turn to start, you lose all power to everything, all the lights go out, radio goes dead, no power to anything. That's why I thought it was the battery or the solenoid but both test out fine. They did a charge and load test on the battery yesterday at Autozone and it came through in the green both times. I've traced through all the wires under the hood and everything looks fine, but just to be sure I replaced both battery cables with no change. The starter doesn't even try to turn when you turn the key, there just isn't any power whatsoever.
 
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Old Aug 5, 2006 | 08:09 PM
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So try the wire test that I told you to the booted term on the sol...Let me know.

Make sure its in park.
 
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Old Aug 5, 2006 | 09:28 PM
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Nope, nothing turned. The second I touched the terminal with the wire, there was a loud CLICK that sounded like it came from the solenoid, then nothing. As soon as I hooked everything back up again (pulled the wire, re-attached the wire to that terminal), I had no power whatsoever, no headlights, nothing.
 
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