1996 Bronco/F-Series

Section 03-06: Starting System

1996 F-Series and Bronco Workshop Manual

DIAGNOSIS AND TESTING

Pinpoint Tests

NOTE: Use Rotunda Digital Volt-Ohmmeter 014-00407 or equivalent to perform electrical pinpoint tests.

PINPOINT TEST A: STARTER MOTOR CRANKS ENGINE SLOWLY OR NO CRANKING WITH RELAY/SOLENOID CLICKING OR CHATTERING

A1 CHECK CONNECTIONS AT BATTERIES

Inspect all battery cable connections for looseness and corrosion.

Are battery connections clean and tight?

Yes	No
GO to A2.	CLEAN and TIGHTEN connections at batteries.

A2 STARTER LOAD TEST

Perform starter load test. Refer to Component Tests in the Diagnosis and Testing portion of this section.

Did starter pass load test?

Yes	No
GO to A3.	TEST batteries. REFER to Section 14-00. If batteries are OK, GO to A4.

A3 CHECK FOR EXCESSIVE RESISTANCE

Perform voltage drop tests. Refer to Component Tests in the Diagnosis and Testing portion of this section.

Did starter circuit pass voltage drop test?

Yes	No
GO to A4.	CLEAN circuit connection as necessary.

A4 STARTER NO-LOAD TEST

Perform starter no-load test. Refer to Component Tests in the Diagnosis and Testing portion of this section.

Did starter pass no-load test?

Yes	No
Slow cranking is caused by excessive engine drag.	REPAIR or REPLACE starter.

PINPOINT TEST B: STARTER MOTOR DOES NOT CRANK ENGINE

B1 CHECK CONNECTIONS AT BATTERIES

Inspect the battery terminals for loose or corroded connections.

Are battery connections clean and tight?

Yes	No
GO to B2.	CLEAN and TIGHTEN connections at batteries.

B2 CHECK BATTERIES

Check batteries. Refer to Section 14-00.

Are the batteries OK?

Yes	No
GO to B3.	CHARGE or REPLACE the batteries.

B3 STARTER RELAY FUNCTION

CAUTION: Make sure transmission is in neutral and parking brake is applied.

Connect remote starter switch between battery terminal at starter relay and starter relay S terminal.
Press remote starter switch button.

Does starter crank engine?

Yes	No
If equipped with an automatic transmission, GO to B4. If equipped with a manual transmission, GO to B7.	If relay does not click, GO to B9. If relay clicks, GO to B10.

B4 BATTERY FEED TO STARTER RELAY

With key in START position, check for battery voltage at starter relay S terminal (R/BL).

Is battery voltage present?

Yes	No
GO to B9.	GO to B5.

B5 BATTERY FEED FROM TRANSMISSION RANGE (TR) SENSOR OR PARK/NEUTRAL POSITION (PNP) SWITCH

With key in START position, check for battery voltage at TR sensor/PNP switch terminal (R/LB).

Is voltage present?

Yes	No
REPAIR open in Circuit 32 (R/LB) between relay and sensor/switch.	GO to B6.

B6 BATTERY FEED TO TRANSMISSION RANGE (TR) SENSOR OR PARK/NEUTRAL POSITION (PNP) SWITCH

With key in START position, check for battery voltage at TR sensor/PNP switch terminal (W/PK).

Is voltage present?

Yes	No
CHECK TR sensor/PNP switch adjustment. REFER to Section 07-14A or Section 07-14B. REPLACE sensor/switch, if properly adjusted.	REPAIR open in circuit between sensor/switch and starter relay.

B7 BATTERY FEED TO CLUTCH PEDAL POSITION SWITCH

With key in START position, check for battery voltage at CPP switch terminal (R/LB).

Is voltage present?

Yes	No
GO to B8.	REPAIR open in circuit between ignition switch and CPP switch.

B8 CLUTCH PEDAL POSITION (CPP) SWITCH CONTINUITY

With key in START position and clutch pedal pressed, check for battery voltage at CPP switch terminal (W/PK).

Is voltage present?

Yes	No
REPAIR open in circuit between CPP switch and starter relay.	REPLACE CPP switch.

B9 STARTER RELAY GROUND

Check for continuity between relay mounting bracket and clean chassis ground.

Is there continuity?

Yes	No
REPLACE starter relay.	CLEAN ground connection.

B10 BATTERY FEED TO STARTER SOLENOID

With key/push-button switch in start position, check for battery voltage at starter solenoid S terminal (R/BL).

Is battery voltage present?

Yes	No
GO to B11.	REPAIR open in Circuit 32 (R/BL) between relay and solenoid.

B11 STARTER SOLENOID

Check starter solenoid. Refer to Component Tests in the Diagnosis and Testing portion of this section.

Is starter solenoid OK?

Yes	No
REMOVE starter and perform no-load test. REFER to Section 03-06A or Section 03-06B for removal procedure. REFER to Component Tests in the Diagnosis and Testing portion of this section for test procedure.	REPLACE starter solenoid.

PINPOINT TEST C: STARTER MOTOR SPINS BUT DOES NOT CRANK ENGINE

C1 CHECK FLYWHEEL

Remove the starter motor. Refer to Section 03-06A or Section 03-06B.
Inspect flywheel and drive pinion for damage or excessive wear.

Is flywheel or drive pinion worn or damaged?

Yes	No
REPLACE the flywheel and drive pinion. REFER to appropriate engine section in Group 03.	GO to C2.

C2 OVERRUNNING CLUTCH

Check operation of overrunning clutch. Refer to Drive Pinion Test under Component Tests in the Diagnosis and Testing portion of this section.

Does overrunning clutch operate properly?

Yes	No
DISASSEMBLE starter and INSPECT starter.	REPLACE overrunning clutch.

PINPOINT TEST D: UNUSUAL STARTER MOTOR NOISE DURING STARTER MOTOR OVERRUN

D1 CHECK STARTER MOTOR MOUNTING

Inspect the starter motor mounting.
Check the starter motor mounting bolts for looseness.

Is the starter motor mounted properly?

Yes	No
GO to D2.	REMOUNT or REPLACE the starter motor.

D2 CHECK STARTER DRIVE ENGAGEMENT

Remove the starter motor.
Inspect the starter drive and flywheel for damage. REFER to Pinpoint Test C1.

Are the starter drive and flywheel OK?

Yes	No
CHECK drive pinion overrunning clutch. REFER to Component Tests in the Diagnosis and Testing portion of this section.	REPLACE as necessary.