• HEADINGS
  • DESCRIPTION
  • TROUBLE SHOOTING
  • ON-VEHICLE TESTING
    • STARTER LOAD TEST
    • STARTER CIRCUIT VOLTAGE DROP TEST
  • BENCH TESTING
    • STARTER NO-LOAD TEST
    • ARMATURE OPEN CIRCUIT CHECK
    • ARMATURE GROUNDED CIRCUIT TEST
  • OVERHAUL
  • STARTER SPECIFICATIONS
  • TORQUE SPECIFICATIONS
  • WIRING DIAGRAMS
• FIGURES
  • Fig. 1: Identifying Starter Solenoid Terminals
  • Fig. 2: Identifying Starter No-Load Test Connections
  • Fig. 3: Testing Armature For Grounded Circuit
  • Fig. 4: Exploded View Of Motorcraft Starter Motor Assembly
  • Fig. 5: Starter System Wiring Diagram
• TABLES
  • STARTER SPECIFICATIONS
  • TORQUE SPECIFICATIONS

STARTER

1996 ELECTRICAL Ford Motor Co. Starter

DESCRIPTION

A gear reduction starter with permanent magnet fields is used. An internal planetary gear reduction unit provides increased cranking torque. The starting system includes a 6-pole, 4-brush starting motor with solenoid-actuated drive, battery, starter/ignition switch, transmission range switch (A/T), clutch pedal position switch (M/T), starter relay (some models) and associated circuitry.

Power to ignition switch is provided from IGN SW fuse in interior fuse panel.

TROUBLE SHOOTING

NOTE:

See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION section.

ON-VEHICLE TESTING

CAUTION:

When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section before disconnecting battery.

STARTER LOAD TEST

1. Connect starter load tester and voltmeter to battery terminals. Ensure no current is flowing through the ammeter and carbon pile of tester. Disconnect terminal "S" of starter relay. See Fig. 1 .
2. Connect remote starter switch between terminal "S" and positive battery terminal. Ensure transmission is in Park on A/T models, or Neutral on M/T models.
3. Crank engine with ignition off. Note voltmeter indication, then stop cranking engine. Adjust carbon pile to match voltage obtained while cranking. Read ammeter. Replace or repair starter if current exceeds specification. See STARTER SPECIFICATIONS .

Fig. 1: Identifying Starter Solenoid Terminals
Courtesy of FORD MOTOR CO.

STARTER CIRCUIT VOLTAGE DROP TEST

NOTE:

If starter cranks slowly and battery is okay, perform following test.

1. Check engine ground strap and negative battery cable connections and repair as necessary. Prevent engine from starting by disabling ignition system. Ensure transmission is in Park or Neutral. Connect remote control starter switch between starter solenoid "S" terminal and positive battery terminal. See Fig. 1 .
2. Connect voltmeter positive lead to positive battery terminal. Connect voltmeter negative lead to "M" terminal on starter solenoid. See Fig. 1 . Crank engine using remote starter switch while observing voltmeter. If voltmeter reads greater than 0.5 volt, go to next step. If voltmeter reading is less than 0.5 volt, starter feed circuit is okay, repair or replace starter.
3. Move voltmeter negative lead to "B" terminal on starter solenoid. Crank engine and record voltmeter reading. If voltmeter reading is still greater than 0.5 volt, excessive resistance is present in positive battery cable or cable connections. If voltmeter reads less than 0.5 volt at "B" terminal, check cable connections at starter solenoid. If okay, replace starter solenoid.

BENCH TESTING

STARTER NO-LOAD TEST

1. Connect starting system test equipment following manufacturer instructions. See Fig. 2 . Ensure carbon pile rheostat of starter tester is turned off.
2. Connect heavy wire between negative battery terminal and starter frame. Connect another heavy wire between positive battery terminal and "B" terminal of starter solenoid.

   CAUTION:

   Ensure starter is securely mounted in vise while energizing as starter will move or jump.

3. Connect a jumper wire between battery positive terminal and "S" terminal on starter solenoid. See Fig. 1 . Ensure starter drive ejects completely and starter spins rapidly. Observe ammeter reading.
4. If ammeter is not available, note voltage reading while testing. Using carbon pile load tester, apply load until voltmeter reading is equal to test voltage. Read amperage on carbon pile tester. Replace starter if current draw is more than specified. See STARTER SPECIFICATIONS .

Fig. 2: Identifying Starter No-Load Test Connections
Courtesy of FORD MOTOR CO.

ARMATURE OPEN CIRCUIT CHECK

An open armature circuit can be detected by inspecting commutator for burning. If burning is present, replace armature assembly. Check for damage to other related components.

ARMATURE GROUNDED CIRCUIT TEST

Using an ohmmeter, check for continuity between any commutator segment and armature laminations. See Fig. 3 If ohmmeter indicates less than infinite resistance, armature is shorted and must be replaced.

Fig. 3: Testing Armature For Grounded Circuit
Courtesy of FORD MOTOR CO.

OVERHAUL

NOTE:

Use illustration for exploded view of Motorcraft starter motor assembly. See Fig. 4 .

Fig. 4: Exploded View Of Motorcraft Starter Motor Assembly
Courtesy of FORD MOTOR CO.

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

Application		Specification
Brush Length
New		.55-.66" (14-17 mm)
Service Limit		.25" (6.4 mm)
Brush Spring Tension		64 ozs. (2.3 kg)
Commutator
Diameter		(1)
Runout		(2) .005" (.13 mm)
Starter Load Test
Maximum Current Draw		130-220 Amps
Starter No-Load Test
Maximum Current Draw		60-80 Amps
(1) Not specified by manufacturer. (2) Replace armature if runout exceeds specification.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application	Ft. Lbs. (N.m)
Starter-To-Engine Bolts	15-20 (20-27)
INCH Lbs. (N.m)
Brush End Plate Bolts	55-80 (6-9)
Cable Terminal Nut	70-130 (7.9-14.7)
Solenoid Bolts	45-85 (5-10)
Solenoid Terminal Nuts	80-124 (9-14)
Through-Bolts	55-75 (6.2-8.5)

WIRING DIAGRAMS

Fig. 5: Starter System Wiring Diagram