2007 f-150 fx4 5.4L super crew
 

About two weeks ago I came out of class ready to get home and when I turned my key, nothing. All gauges worked, I can here the fuel pump working, but absolutely no noises around the starter. After a few more try's it started and gave me no more problems. Two days later it happened again but this time it didn't start after two hours of trying. I first went to the battery, all connections were clean and tight, had the battery checked and that turned out fine. Next I pulled every relevant fuse in the fuse box on my passenger side, all seemed fine. Switched out my starter and pcm relays and had no results. Tried putting in neutral and nothing happened. I finally had to run a wire from my starter solenoid to my battery( essentially bridging the starter). I drove back home and took it to our mechanic. In about 45 minutes he did a master reset on the trucks computer, reset the pcm and all of that good stuff. The truck started 25 to 30 times and everything seemed fine. I went back out of town and thought all was well until I stopped at a gas station two hours away from home, came back out and no start. I hate having to lift the hood to start it and have already gotten plenty of "it's because it's a ford" comments. Maybe a new pcm is what I'm thinking at this point but would hate to shell out 200 dollars for no reason. I'm sick of it and was hoping someone has had the same issue and found a solution. All ideas would be appreciated!

Have you checked all the ground wires and starter wires for corrosion?

Yes I have @techrep, I forgot to mention it but I spent some time doing that as well.

removed

Or ignition switch

Safety disconnect switch on shifter?

Or the starter itself. Next time it doesnt start try hitting the starter with something.

Same thing happened recently to mine, wouldn't crank unless I bridged it, and then a couple days later not even bridging would work. Bought a new starter and replaced it and is working fine now. Definitely try the starter.

I took my starter off and had it checked at NAPA, they said it was fine. I cleaned all of my connections on it as well. I'll try a new one though possibly. It seems funny to me that a master reset fixed it though. My pats system isn't throwing a code but I'm wondering if something is being shorted.

Well personally I dont trust NAPA or any other chain store when testing batteries, alternators or starters. To many times i hear that they tell people they are fine when they are not. You would think its the other way around.