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    1958 Dodge Royal 5.7L 4BL 8cyl

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    Ford Pick-Ups/Expedition/Navigator 1997-2000

    Starter

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    TESTING



    Voltage Drop Test

    The battery must be in good condition and fully charged prior to performing this test.

    1. Disable the ignition system. Verify that the vehicle will not start.
    2.  
    3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
    4.  
    5. Turn the ignition key to the START position and note the voltage on the meter.
    6.  
    7. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
    8.  
    9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
    10.  
    11. Turn the ignition key to the START position and note the voltage on the meter.
    12.  
    13. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    14.  

    Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

    REMOVAL & INSTALLATION



    4.2L, 4.6L, 5.4L and 6.8L Engines


    Click image to see an enlarged view

    Fig. Fig. 1 Remove the starter terminal cover



    Click image to see an enlarged view

    Fig. Fig. 2 Remove the cables from the starter terminals



    Click image to see an enlarged view

    Fig. Fig. 3 If equipped, remove the ground cable retaining nut from the stud and remove the ground cable



    Click image to see an enlarged view

    Fig. Fig. 4 Remove the two starter retaining bolts-4.2L engine shown



    Click image to see an enlarged view

    Fig. Fig. 5 Remove the two starter retaining bolts-4.6L engine shown, 5.4L and 6.8L engines similar

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the starter terminal cover.
    6.  
    7. Remove the terminal nut and separate the battery starter cable from the starter motor.
    8.  
    9. Disconnect the solenoid S terminal connector, if equipped with a starter mounted solenoid.
    10.  

    To disconnect the hard-shell connector from the solenoid S terminal, grasp the plastic shell and pull off; do not pull on the wire. Pull straight off to prevent damage to the connector and S terminal.

    1. Remove the starter motor retaining bolts.
    2.  
    3. Remove the starter motor from the vehicle.
    4.  

    To install:

    1. Place the starter motor in position and install the starter motor retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-27 Nm).
    2.  
    3. Install the battery starter cable and a terminal nut to the starter motor. Tighten the terminal nuts to 79 inch lbs. (9 Nm).
    4.  
    5. Connect the solenoid S terminal connector, if equipped with a starter mounted solenoid.
    6.  
    7. Install the starter solenoid safety cap, if equipped.
    8.  
    9. Lower the vehicle.
    10.  
    11. Connect the negative battery cable.
    12.  
    13. Start the engine several times to check starter motor operation.
    14.  

    5.8L and 7.5L Engines
    1. Disconnect the negative battery cable.
    2.  
    3. Raise and safely support the vehicle securely on jackstands.
    4.  
    5. Remove the starter cable heat shield(s).
    6.  
    7. Disconnect the wiring at the starter.
    8.  
    9. Remove the starter mounting bolts and remove the starter.
    10.  

    To install:

    1. Install the starter and tighten the retaining bolts 15-20 ft. lbs. (20-27 Nm).
    2.  
    3. Attach the wiring and install the heat shield(s).
    4.  
    5. Lower the vehicle and connect the negative battery cable.
    6.  
    7. Check for proper operation.
    8.  

    7.3L Diesel Engine
    1. Disconnect the negative battery cable.
    2.  
    3. Raise the front of the truck and install jackstands beneath the frame. Firmly apply the parking brake and place blocks in back of the rear wheels.
    4.  
    5. Label and detach the wiring from the starter motor terminals.
    6.  
    7. Loosen the starter motor retaining bolts.
    8.  
    9. Remove the starter retaining bolts while supporting the starter motor and remove the starter from the vehicle.
    10.  

    To install:

    1. The installation is the reverse of removal. Tighten the starter retaining bolts to 15-20 ft. lbs. (20-27 Nm)
    2.  

    RELAY REPLACEMENT





    Click image to see an enlarged view

    Fig. Fig. 6 Remove all the necessary cables from the relay



    Click image to see an enlarged view

    Fig. Fig. 7 Remove the two relay retaining bolts and remove the relay from the vehicle

    1. Disconnect the negative battery cable from the battery.
    2.  
    3. Remove the nut securing the positive battery cable to the relay.
    4.  
    5. Remove the positive cable and any other wiring under that cable.
    6.  
    7. Label and remove the push-on wires from the front of the relay.
    8.  
    9. Remove the nut and disconnect the cable from the starter side of the relay.
    10.  
    11. Remove the relay mounting bolts and remove the relay.
    12.  

    To install:

    1. Install the relay and mounting bolts. Tighten the mounting bolts until snug.
    2.  
    3. Attach all wiring to the relay.
    4.  
    5. Connect the negative battery cable.
    6.  

     
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