91 F-250 won't start...relay related? Fixed - Diesel Forum

GringoEJS · 09-29-2005, 12:59 PM

Well, the F-250 has always been a champ until now, and I only drive it about once a week. I did an oil change and then went to move it when it just turned over and over until it drained the battery. It had been getting kind of hard to start lately,, usually firing up on the 3rd or 4th try.
Well, I have always heard the click-click-click that would bring the volts from 12 to 8, but on this occasion, there is another sporatic clicking like some relay is shorting out or something. It also is drawing voltage and figure it may be interfering. I have traced the sound to a black box bolted down to the left of the fuse panel under the dash. Says Motorcraft with a part number, but nothing else. What is this?
Second, I figured I would swap in another battery and try and start the truck again, but now however each time I turn the key to turn it over, I just get a loud click at another box on the passenger fender about a foot from the battery. The box has a battery wire and wire to starter among other wires. Did this go bad all of a sudden too. BTW, the battery cables were on tight...
Thanks

aaklingler · 09-29-2005, 05:58 PM

The box on the pass. fender is the starter relay, its cheap, you could try replacing. Charge your batteries up and take them to autozone or somewhere and have them individually load tested. If you buy new get at least 875CCA each. How long was your wts light on the first time? I don't know what the box is under the dash. You could call ford and give them the #.

GringoEJS · 09-30-2005, 12:53 AM

Allen, thanks alot. It never crossed my mind to call Ford. It turns out that the black box is the intermittant wiper switch and it was malfunctioning. I unplugged the switch and no longer have a voltage drain. Then the click at the starter relay was just the starter kicking out but not spinning. I thought the 2 problems were related, but they weren't. I had actually pulled the starter off and it tested good, but after swapping relays with no change, I got under the truck while my g/f turned the key and saw the solonoid sparking. Everything was tightened down, just the solonoid had broken somehow.
To make a long story short, I swapped in a new starter (replaced the other 1 year and 1 day ago) and the truck fired right up.
Problem is fixed...This site rocks!