I have an 06 FX4 Supercrew with a 5.4 and am in need of some help. The starter relay clicks but the starter doesn't turn over. I can hear the relay click but no starter action. I swapped relays but still nothing. It has a new starter and I just got done putting a new power steering pump and pressure line, took it for a drive, pulled it into the shop and shut it off. Went to start it and nothing but relay clicks. Any help is greatly appreciated.

 

The obvious.... load tested the battery? Checked the alternator output?

 

My wife got online and found a post about disconnecting the negative battery cable for 10 minutes to reset the anti theft. I tried it and it started. The alternator is putting out 14.15 volts at the battery. So am I dealing with a finicky anti theft? I do have only 1 key and its not the original key. I may get a new battery just to eliminate it.

 

If it were the PATS system , I don't think you would hear the relays for the starter.. would not allow you to get that far into the starting process.

 

Check the solenoid nut on the starter is snug.

I don't remember exactly which one it is so won't hurt to tighten all three nuts down. Fairly easy to access from below.

 

As I understand the theft system, If triggered the dash LED will begin flickering while you crank. You'll get turnover but the fuel is cutoff. But that's just from other's anecdotes, I've never witnessed it myself so I could be wrong. I had your issue today but solved it by smacking the solenoid. If yours is new I'd suspect some wiring, bolts, or anchors have loosened with driving.

 

Had a chance to get the battery load tested today and it failed. Wouldn't charge above 40%. Replaced it tonight and everything seems to be working again. Hooked up the solus edge scanner checked and cleared codes and programmed 2 new keys. Now I need to fix the broken exhaust manifold studs and put a new transfer case shift motor in.

 

Went for a drive today and it started just fine, got back to the shop and shut it off and a few minutes later went to start it again and nothing just relay clicks. I put it in the air and started looking at the shift cable and reverse/neutral safety switch.The shift looks to have been replaced before i purchased the truck but it looked like it was out of adjustment. The cable grommet was not seated in the hole. I removed the bracket that holds it and the neutral switch and cleaned the switch, reinstalled everything and adjusted the shift cable and the neutral switch. It now appears to me that all of my no start problems were because of a neutral switch and shift cable that were out of adjustment. If it happens again I"ll let you all know.

 

Even though I've replaced several of those, I still forget about them... never seen one result in "clicking" though, usually it's start/no start. Your battery failed the load test, so that wasn't money wasted. Glad it seems to be working.