Hello. This is my first post here. I have read the forum several times and it has helped me with various problems with my Aerostar. It is a 95 model shorty cargo van with the 3.0 engine and AT. My problem started last week. I noticed the starter sounded draggy like the battery was weak. I had the battery checked at AZ and it was good even under load. A few days later when I went out to start it there was just a click. I took the starter off and had it checked. It needed the brushes replaced....otherwise in good shape the man at the shop said. I put the repaired starter back on and again all I get is a click. I put the voltmeter on the battery and it reads 12.7 volts. At any rate I put the battery on a charger for a while and when I try to start it it fires right up. When I shut it off again all I get is a click. I put the charger back on the battery and turn it up to boost. It starts up but the ammeter pegs out to the positive and the amp light comes on and then the ABS light comes on. I turn it off. I disconnect the charger. The voltmeter still reads good at the battery. Now when I turn the key on there is nothing....no click...no lights on the dash. The overhead light has a very faint glow. I removed the battery and alternator figuring the voltage regulator is shot. I took the alternator to an electrical shop and they confirmed that it was bad. I had the battery retested and again it tested good under load. I installed the new alternator and when I turn the switch the dash lights up as normal and I hear the fuel pump priming and when I try to crank it....all I hear is click. I try again and the dash does not light up and it will not even click. I disconnect the battery and reconnect. Again the dash lights up but I only get a click when turn it to crank. I repeated this several times...after disconnecting and reconnecting the battery the dash would light up as usual and there was a a click on the first attempt. After that it was completely dead until I did the disconnect reconnect procedure again. I have checked the battery cables. I have brightened up the ends of the ground wire from the starter to the body. I have done searches on here but I can't find any relevant information. I'm hoping someone has some ideas. I would be grateful for any help.

Jake

 

I would suspect a bad/borline weak cell or 2 in the battery. When a battery is tested for in general- load and not each cell (with a volt meter), the battery may still test good but in fact need replacement.

 

Thanks for the suggestion. I got to thinking that you might be right so I took the battery out of my truck and swapped it with the one in the Aerostar. I know this battery is good. Same result....... so that rules out the battery as a possibility.

 

It sounds like a bad connection. Check the battery cable stud on the starter relay. In fact, check both studs on the starter relay to make sure the lugs are clean and the nuts are tight. Also check the battery terminals on the ends of the cables. Use a wire brush to clean them off, and clean the battery terminals themselves. When they're corroded, it does not matter how tightly you tighten the bolts on them, they will not conduct enough current to start the engine.

 

Is the starter relay located on the inside fender well above the battery?

 

Yes it is, driver side. When I had this happen to me. I had the cable ends cut off and re crimped with new clamps. or you can buy some quality audio system clamps. see pictures of system install Audio System - Windows Live I always use a wire steel brush when I have electrical wiring off, so I can clean them up.

 

Hey....that was the problem. I cleaned all the cables, brightened everything up and put it back together. It started right up. I never thought a bad connection would make so much difference. Thanks to everyone who responded. This forum is great! Jake

 

Great job. Now that you've cleaned off those terminals, you might want to protect them so they won't corrode as quickly. Covering them with a little bit of grease helps. If you don't want to take them apart again just to grease them, you can get some LPS3 or chain wax and spray onto the terminals.