Hello,

[2004 F-150 3v 5.4 V8]
Summary: When trying to start the vehicle, when I turn the key I hear a single click under the dashboard. Not multiple clicks, just one single click, and nothing else. It does not sound like it is coming from the starter solenoid, but I am not 100% sure. It really sounds like it is coming from right under the center console.

Background: Truck has been having intermittent problems starting for the past year. To remedy the issue, I would wiggle the negative battery cable, and that would get it to start. (When this happened, the interior lights and whatnot would not be on. I could tell I had found the "sweet spot" by wiggling that negative cable, and watching for the lights to come on. This is different from the situation I am dealing with now.) I did notice some broken strands at one point, so I cut the wire back, removed some sheathing and reconnected the wire hoping to get a better connection.

This seemed to fix the issue for 2-3 months, then started having trouble starting again. I decided to replace the main negative battery cable. Since I was going to be down near the starter, I thought "why not replace the starter too!" After all these things do tend to wear out, and it appeared I had the original starter with the truck. After wrestling with that darn third top bolt for 5 hours, I was able to pull out and replace the starter. Note; I did not reconnect that third top bolt, as I wanted to verify it would work before tackling that horrendous task. Got the new starter in, and new negative battery cable connected, but it would not start.

At this time, I figured there might be more to the negative battery cable than I can see, so I removed it, and put the old cable back in. I cleaned all the connections at the battery and at the starter, but it still would not start. I then took out the new starter, thinking it was a lemon, and put the old one back in. (Still no top #3 bolt...) I bench tested the new starter, and it appears to work correctly. New starer appears to engage and spin up without issue.

Current Troubleshooting \ Status:

• All interior lights and gauges, radio come on fine. Headlights come on just fine.
• Checked power on battery, getting 12.6 V.
• Connected a jump box when trying to start "just in case". (No difference.)
• Recharged battery "just in case". (No difference)
• Tested & validated continuity on the shorter ground cable going from the battery to the frame.
• Tested & validated continuity on ground cable going to starter.
• Tested & validated continuity on positive cable going to starter solenoid.
• Changed out / replaced PCM relay (R203). [Interior, near passenger foot area]
• Changed out / replaced Starter relay (R01). [Interior, near passenger foot area]
• Checked all fuses which I felt could be remotely related to starting. [Interior, near passenger foot area]
• Cleaned & recleaned all connections at starer, starter solenoid, and battery.
• Shifting out of Park and back into Park.

I am fairly certain the engine has not seized. I am pretty meticulous about changing the oil. I also did change out the cam phasers about a year ago, not sure if that would have anything to do with this.

Here is what I am planning to do, but I don't think they are going to make much difference or are longshots:

• Put that nasty third bolt back in. (The starter is very solidly bolted in, but I guess this could be an issue.)
• Testing the other solenoid terminal to see if it gets power when the key is turned.(I am alone, so it just hasn't been convenient to chase somebody down to try this out. I suspect it will not get power, as I don't believe turning the key is telling the solenoid to activate.)
• Trying to start it using the "screwdriver" starting method I have heard about. (Just freaks me out a little; those sparks and pops from bench testing were pretty big...)
• Replacing all fuses. (I've heard a fuse can test good, but be bad under a full load...)

I am really hoping somebody might be able to point me in the right direction to solve this issue! Thanks!

 

if you think its a grd problem you can take your battery jumper cable and go from neg battery to starter frame .
it helps to string a wire from the solenoid point on starter to see if you get signal there without crawling under there . you can jump it right to positive to see if it cranks .if it won't then either pos cable bad or starter bad . look at head lights do they dim or go out during crank attempt -maybe bad battery .
positive cable to starter tends to corrode up more than negative

 

Not necessary at this time.
Probably a waste of time (and fuses). There is no evidence that a fuse is faulty.
Get sure of the origin of the sound. Guessing doesn't help much.... Save until later, though, see below.
That might be useful... later.
Maybe later.

Start with some more basic stuff. Have to figure out if prerequisites to cranking are present.
1. What does the THEFT light do when you turn the ignition switch from OFF to RUN? This truck is equipped with a starter interrupt. If PATS ain't happy, it won't crank.
2. What does the odometer do at the same time?

 

the transmission shift interlock (press foot on brake to start)???...

Bill