No crank issue on 2004 Ford Expedition NBX 5.4
First some background into the problem and follow ups done.
Over two years ago I began having occasional no crank issues with the vehicle. At that time, usually it would crank and start after waiting a few minutes or so. Over time the no crank issue became worse. It other words, it became more frequent and often had to wait longer periods of time for it to start(crank). Sometimes I even had to wait for the next day to get it started. Eventually, the no crank issue seem to reach a critical stage, in which I installed a new starter and new ignition switch. A new battery was installed shortly before that. After installing these new parts, the vehicle started for just a few times, and I encountered the same no crank issue. In an effort to explore other possibilities, I wondered if the ignition tumbler was the problem. Coincidently, at the point I happened to pull the tilt steering all the way down and the vehicle started. I put it back in the full tilt up position and the vehicle would not start, but when I would put the steering down, it would crank and start normal. I continued using the vehicle for a few months but eventually no matter how the tilt steering was positioned the vehicle would not start. One time only, I grabbed the wiring harness under the dash and the vehicle started up. However, the next time I tried to start the vehicle, it would not crank, no matter what I tried.
In February 2017, I tried the vehicle and it started fine every consecutive time for about a week, as I moved it in and out of my garage to be able to work on my wife’s car a few times. However, after about a week or so, I couldn’t get it to crank, on numerous daily attempts. I began to perform a few troubleshooting tests, and even removed the remote starter, just in the off chance that it was causing a no crank issue. However, it did not solve the issue. At one point I touched the relays in the passenger side kick panel area, to feel for the click, and at the same time turning the key.
The vehicle suddenly started, and I did this 3 or 4 times over a few minutes period, and each time I would do this the vehicle would crank and start normal. However, I’ve had no luck getting it to start since.
I removed the Central Fuse Panel just to check if anything seemed burnt, damaged or corroded, but everything looked perfect. I checked a few things with the test light, as follows: The constant power wire at the ignition switch tested okay. The crank wire at the ignition switch (with the key to start position) tested okay. The started relay tested with power on pin 30 on the fuse panel. With the key in start position, no power on pin 86. I’m still thinking there may be an open somewhere in the wiring under the dash, or a grounding problem, as the odd cranking situation seems very erratic. Also, the dash lights acted different than normal during this no crank, and sometimes the radio would power on when trying to crank. Is there any way to direct wire to the starter, or what would be the next steps or tests to perform to troubleshoot this issue? I would like to begin troubleshooting the vehicle again on Monday, April 17, 2017. Any help would be appreciated.