Ford Freestar, Monterey 2004-2006

Starter

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Disconnect the starter electrical harness.
  6.  
  7. Remove the upper starter bolt.
  8.  
  9. Support the starter and remove the lower bolt.
  10.  
  11. Remove the starter from the vehicle.
  12.  

To install:

Click image to see an enlarged view

Fig. Starter motor mounting-3.9L and 4.2L engines

  1. Position the starter in the vehicle.
  2.  
  3. Install the upper and lower bolts. Tighten to 21 ft. lbs. (28 Nm).
  4.  
  5. Connect the starter electrical harness.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative battery cable.
  10.  

Testing & Troubleshooting




CAUTION
When repairing the starter motor or carrying out other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times. Failure to follow these instructions can result in personal injury.


WARNING
A protective cap or boot is provided over the battery input terminal on all vehicle lines and must be installed after repairing. Be sure to disconnect the battery ground cable before repairing the starter motor.

Connect the 73III Automotive Meter at the component terminal rather than at the wiring end connector. Making a connection at the wiring end connector could result in false readings because the meter will not detect a high resistance between the wiring connector and the component.

Feed Circuit Test
  1. Make sure the battery is fully charged.
  2.  
  3. Disconnect the Inertia Fuel Shutoff (IFS) switch.
  4.  
  5. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
  6.  
  7. Connect the 73III Automotive Meter positive lead to the battery positive (+) post. Connect the negative lead to the M-terminal.

    Click image to see an enlarged view

    Fig. Starter motor feed circuit test connections

  8.  
  9. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.8 volt or less.
  10.  
  11. If the voltage reading is 0.8 volt or less, go to the Ground Circuit Component Test.
  12.  
  13. If the voltage reading is greater than 0.8 volt, this is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid. Move the 73III Automotive Meter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading at the B-terminal is lower than 0.8 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts.
  14.  
  15. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop reading is still greater than 0.8 volt when checked at the M-terminal and less than 0.8 volt when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
  16.  
  17. If the voltage reading taken at the solenoid B-terminal is still greater than 0.8 volt after cleaning the cables and the connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new positive battery cable.  
  18.  

Ground Circuit Test

A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. Check the voltage drop in the ground circuit as follows:

  1. Connect the 73III Automotive Meter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal.

    Click image to see an enlarged view

    Fig. Starter motor ground circuit test connections

  2.  
  3. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.5 volt or less.
  4.  
  5. If the voltage is more than 0.5 volt, clean the negative cable connections at the battery, the body ground connections, and the starter ground connections. Retest.
  6.  
  7. If the voltage is more than 0.5 volt, install a new cable. If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor.
  8.  

 
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