My 2003 F150 XLT will not start. Here is the history for the past 2 weeks. I first tested the battery and it tested low so I replaced it, 850CCA. That didn't fix the problem. I then replaced the starter, which was only 2.5 years old, and then it worked for maybe a week and now it is doing the same thing. I changed out the started with a new one and the same results. The starter solenoid is being powered but the starter doesn't seem to have enough energy to engage the flywheel. If you rotate the flywheel it will sometimes start. I cleaned the battery contacts and I did notice some green corrosion on the eyelet on the starter cable from the battery. Could this be it if the wire is corroded through? I cant come up with anything else. Does anyone know the part number for the eyelet. Ford doesn't seem to sell just the eyelet, only the entire cable assembly for $600 ish.

Thanks

 

Perform a voltage drop test on the battery supply to starter, bad connection.

A replacement eye connector can be installed if yours is bad..

 

Can we ask who did or is going to do the work, ? Thanks.

 

I did the work.

 

What would I consider a passing voltage drop?

 

Connect the meter to the positive terminal of battery and the main terminal on starter, crank the starter, anything over 0.5vdc is excessive..

 

You might want to check the junction block on the driver's side fender well in the engine compartment.
It has tendency to get corrosion and not always be visable.A good Preventative maintenance move would be to loosen the connections there , clean them and reassemble them. Have had problems in that area before..

 

I replaced the connector on the battery cable at the starter and that seems to have resolved the issue. Thanks.

 

Glad you have resolved your issue.