I have a 2004 F-150 XLT 5.4L V8, 15K miles. I am having an intermittent “No Start” problem that occurred the first time 16 months ago under warranty. The symptom is that when attempting to start, the solenoid engages (clicks) (maybe it's the starter relay?) but the starter does not crank nor does it draw any current from the battery because I turned the headlights on, turned the ignition and the lights stayed bright. It was towed to the dealership and they said that the starter terminals were corroded. They cleaned them and no more problems until this week. Yesterday, I tried to start but only the solenoid clicked. Maybe it is the starter relay clicking and not the solenoid? I looked at the starter terminals and they looked clean. Battery connections were spotless as the battery was replaced 1 year ago. Just for the heck of it, I pulled off the battery cables, cleaned the posts and clamps, re-attached, tightened, and the truck started up just fine. I wasn't convinced that the problem was solved. This morning I had the same problem again. First I wiggled all the positive and negative wires on the battery clamps and it still wouldn’t start. Second, I removed the negative clamp from the battery, re-attached, tightened, and still wouldn’t start. Next, I removed the positive clamp from the battery, re-attached, tightened, and started just fine. I’m guessing that I’ll have the same problem tomorrow. Why would removing the positive clamp and re-attaching it allow it to start? Any ideas?

 

Were do you live/work?

The reason I ask is I worked for a power plant for a few years and after a few months from the salt water ect ect... I noticed my lights stoped working.. the connectors were corroed but not bad just alittle but that was all it took... I got this gel spark plug stuff from an auto zone and never had anymore problems... Will this work for you? I'm not sure... but it couldn't hurt.

 

I live in south east ohio. We do get salt from the roads in the winter but this is the year driven in the winter (once or twice so far). It started fine the last two days so it's quite puzzling. I think I'll go ahead and replace the starter relay and check all of its terminals and wait and see. Thanks for your post.

 

Have you had the starting system checked? If the solenoid or relay is clicking there has to current draw. I know it's cold as hell down there right now, but would get the starter tested. It has been a while since I worked there, but Autozone used to be able to test it on the truck to see how much draw there is. Not as good as a bench test, but a god start. Have you been under the truck to check out the wiring to the starter?

 

I will check with Autozone about testing the starter on the truck. I did swap the starter relay with the rear defogger relay (both same relay). I checked the connections at the starter and they were tight and clean but didn't remove them. It's started fine the last three days. Thanks for the Autozone tip.

 

I had this same problem and took the truck into my dealer. They quoted me $850. to replace starter and cables, $250 for just the cable. They said the cable and connections were corroded. I did not have the work done.

 

Thanks for the reply. I haven't had anymore issues since swapping the relays, 5 weeks ago and I've been driving it everyday. I'm pretty sure that it will happen again. Will post if I have another problem. Thanks.