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. &nbs