Need some assistance here guys. I have a hobby Bronco that I work on every weekend, but this '99 Expedition I just bought my son is killing me (not to mention my knuckles trying to get to everything). Need some advice...

He drove it last night, let it sit for an hour and now it wont start.

When you turn the key you hear the starter 'clunk' and then it seems to freeze. My first fear was a seizd motor, but the weird thing is all the other electronics go out when I try to crank it - gauges go off, lights out everything like the battery was pulled. When I let off teh key the gauges sweep right and then back to normal. When I try jumping it the battery cables get very hot. - Still thinking (and hoping electrical)

Power is good to the solenoid, but replaced the starter/solenoid anyway - no help. I'm still guessing electrical, but I'm at a loss.

Tomorrow I'm going to try the following

1) bridging the starter with a screwdriver
2) replacing the starter relay
3) replacing battery cables
4) push it off a cliff and buying him a '75 Bronc

Thanks for any help you guys can provide

 

the gauges go out and the wires get hot because the starter is straining and drawing more amps than it should. This causes the voltage to drop below the point that the computer can stay running and your gauges go out. Sounds like you might in fact have a seized motor. At least something is making the starter work harder than it should when trying to turn over the engine. Try putting a socket and breaker bar on the front of the crankshaft and see if you can turn it by hand. Take the starter out and have it tested. Make sure you battery cables aren't corroded.

If none of that helps, go with #4. :-)

 

If not that, then possibly a bad GEM module.

 

Not a chance. The GEM module has nothing to do with the starter circuit.


Do as pitrow suggested and see if you can rotate the flywheel by hand. A seized engine or engine accessory (remove serpentine belt to check for that) will cause exactly your described symptom.

Of course, a bad battery cable or connection can also give much the same display of symptoms. That's why it is strongly suggested to check for seizing first.

In my case, it was a seized A/C compressor clutch that earned my truck a ride home on a flatbed last winter.

Steve

 

Don't dismiss the possibility of a bad connection or battery.

 

Thanks guys. I can turn the motor by hand. I then pulled the belt off and the thing tries to rotate.... The a/c compressor looks shot (and I had a feeling it was going anyway). On my way to pick up a new one. ProjectSHO89 hit it on the head I believe.

I'm off to replace the compressor and then rebuild the xfer case on my Bronc.

Thank you all again.

 

THAT WORKED ! Thanks again guys. I pulled the compressor off and it was frozen solid. Spent about 3 hours replacing it and the beast fired right up. The compressor wasn't even on my "throw parts at it and see what happens list' - guess that's why I'm not cut out to be a mechanic.

The Expy is running, the Bronco is running and my wife likes me again (until I pull in the driveway with that '75 Bronc I mentioned earlier