Intermittent start fail...good click, though
Thread Starter
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6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Intermittent start fail...good click, though
Hi folks,
My girl is a 2002 F-150 XL with manual transmission. Love her and am getting to know her better. My problem developed the last few weeks: intermittently I get a click at the starter relay on the firewall when turning the key in the ignition but no starter engagement (and no start, of course). This goes on for a period of time before correcting itself and starting fine for days on end before happening again. Thus far, new starter (actually 2 to rule out the first replacement starter), clutch safety seems fine with no overtravel and no "click" if not engaged, and there's a new battery in there as well. Fellow I had look at it may have replaced the firewall starter relay also as it appears new.
I can reproduce the click if I jump the firewall relay but that does not produce starter engagement or engine start. Jumping the starter solenoid itself will crank it as will getting it moving and popping the clutch. I'm thinking of replacing the firewall relay since it's cheap and I'm out of ideas so looking for suggestions and troubleshooting advice from you experienced folks as to where to go from here.
Many thanks!
My girl is a 2002 F-150 XL with manual transmission. Love her and am getting to know her better. My problem developed the last few weeks: intermittently I get a click at the starter relay on the firewall when turning the key in the ignition but no starter engagement (and no start, of course). This goes on for a period of time before correcting itself and starting fine for days on end before happening again. Thus far, new starter (actually 2 to rule out the first replacement starter), clutch safety seems fine with no overtravel and no "click" if not engaged, and there's a new battery in there as well. Fellow I had look at it may have replaced the firewall starter relay also as it appears new.
I can reproduce the click if I jump the firewall relay but that does not produce starter engagement or engine start. Jumping the starter solenoid itself will crank it as will getting it moving and popping the clutch. I'm thinking of replacing the firewall relay since it's cheap and I'm out of ideas so looking for suggestions and troubleshooting advice from you experienced folks as to where to go from here.
Many thanks!
Fleet Mechanic
Joined: Jun 2023
Posts: 1,379
Likes: 383
From: WA
Two things happens when you turn the key to Start. Power is sent to the firewall relay and it's plunger is actuated, which is driven down to make electrical contact between the battery and the starter. That's the click at the firewall relay. Power is then transmitted through the relay down to the starter where the relay on the starter does the same thing to drive the gear in to the flywheel and power the starter motor.
All of the cable connections from the battery to the firewall relay to the starter need to be clean and making good contact. I'd start there if you have a new starter and firewall relay. The heat of the starter current can open up a dirty connection.
The firewall relay can wear out also after many starts. The main contact gets dirty. So if it's not new it's probably worth replacing. They're pretty cheap. You'll find the words relay and solenoid used interchangeably around the internet. It's a solenoid-controlled relay.
https://www.rockauto.com/en/catalog/...+solenoid,4188
All of the cable connections from the battery to the firewall relay to the starter need to be clean and making good contact. I'd start there if you have a new starter and firewall relay. The heat of the starter current can open up a dirty connection.
The firewall relay can wear out also after many starts. The main contact gets dirty. So if it's not new it's probably worth replacing. They're pretty cheap. You'll find the words relay and solenoid used interchangeably around the internet. It's a solenoid-controlled relay.
https://www.rockauto.com/en/catalog/...+solenoid,4188
Thread Starter
|
6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Two things happens when you turn the key to Start. Power is sent to the firewall relay and it's plunger is actuated, which is driven down to make electrical contact between the battery and the starter. That's the click at the firewall relay. Power is then transmitted through the relay down to the starter where the relay on the starter does the same thing to drive the gear in to the flywheel and power the starter motor.
All of the cable connections from the battery to the firewall relay to the starter need to be clean and making good contact. I'd start there if you have a new starter and firewall relay. The heat of the starter current can open up a dirty connection.
The firewall relay can wear out also after many starts. The main contact gets dirty. So if it's not new it's probably worth replacing. They're pretty cheap. You'll find the words relay and solenoid used interchangeably around the internet. It's a solenoid-controlled relay.
https://www.rockauto.com/en/catalog/...+solenoid,4188
All of the cable connections from the battery to the firewall relay to the starter need to be clean and making good contact. I'd start there if you have a new starter and firewall relay. The heat of the starter current can open up a dirty connection.
The firewall relay can wear out also after many starts. The main contact gets dirty. So if it's not new it's probably worth replacing. They're pretty cheap. You'll find the words relay and solenoid used interchangeably around the internet. It's a solenoid-controlled relay.
https://www.rockauto.com/en/catalog/...+solenoid,4188
.
Thread Starter
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6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Back to square 1
Well, I swapped out the starter relay on the firewall and it appears that wasn't the issue. So....back to the original question. Any suggestions would be much appreciated.
Thanks folks!
Thanks folks!
Thread Starter
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6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Thank you for the reply! I assume that you mean the wiring directly connected to the starter's solenoid? I'll check that and hopefully find something wrong (strange to say that). I'm thinking it must be the wiring somehow since about every actual piece of hardware (starter & solenoid, firewall starter relay, and battery) has been replaced or checked out. Thanks again!
Cross-Country
Joined: Nov 2014
Posts: 80
Likes: 15
Do a voltage drop test on segments of the wiring.....you will find the problem. You can find how easily with a search.......gonna need a voltmeter......... nothing fancy. Good Luck
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Hotshot
Joined: Jul 2020
Posts: 10,519
Likes: 2,654
From: Near Salt Lake City
Agree with doing the voltage drop test
However, I had to put three starters in my 97 5.4 before I got one that cranked, and then the drive failed 3 days later
I ordered a Ford starter drive from Ebay and fixed it for good hopefully
However, I had to put three starters in my 97 5.4 before I got one that cranked, and then the drive failed 3 days later
I ordered a Ford starter drive from Ebay and fixed it for good hopefully
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Fleet Mechanic
Joined: Jun 2023
Posts: 1,379
Likes: 383
From: WA
I don't see any signs of a meter in any of the OP's posts, even though parts were "checked out". Can't really check them without a meter.
If you're not familiar with how to use a meter this a great time to learn. The wiring is simple and exposed, easy to take measurements. Good luck.
If you're not familiar with how to use a meter this a great time to learn. The wiring is simple and exposed, easy to take measurements. Good luck.
Thread Starter
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6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Thank you very much, folks. I do have a meter and I'm checking the wiring. The checks done previously were by a local shop so I was taking their word for it (well, you give the benefit of the doubt). Running through the wires myself and will hopefully track it down. To start, I was told to try grounding the battery to the engine directly and did so....no go.
Thank y'all again for your time.
Thank y'all again for your time.
Thread Starter
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6th Gear
Joined: Apr 2026
Posts: 6
Likes: 1
Success, I hope
Thanks again for all the help. I may have corrected the issue thanks to the advice. It appears the + cable from the battery wasn't (always) providing proper voltage. Ran through it and did a thorough cleaning and remade the connection itself at the battery. She's happy now. I reckon I'll know in time. Meanwhile I've gotten some good learning in thanks to y'all and the forum.
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