2000-2003 Ford F150 Pickup Truck Workshop Repair Service Manual BEST - 620MB !

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup DESCRIPTION The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral solenoid. Starting system consists of a starter motor, solenoid, battery, ignition switch, Digital Transmission Range (DTR) sensor (A/T) or Clutch Pedal Position (CPP) switch (M/T), starter relay, and interconnecting cables and wires. COMPONENT LOCATIONS COMPONENT LOCATIONS ADJUSTMENTS DIGITAL TRANSMISSION RANGE SENSOR 4R100 Transmission 1. Raise and support vehicle. Disconnect manual shift control cable. Disconnect Digital Transmission Range (DTR) sensor harness connector. Remove manual control lever nut. Loosen DTR sensor bolts. 2. Manual shift lever must be in Neutral. Using Transmission Range Sensor Alignment Gauge (307-351), align DTR sensor slots. See Fig. 2 . Tighten DTR sensor bolts. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . With manual lever in Neutral, connect shift lever control cable. Connect DTR sensor harness connector. Component Location Battery Junction Box Left Side Of Engine Compartment Central Junction Box Under Left Side Of Instrument Panel Clutch Pedal Position Switch On Pedal Assembly Bracket Clutch Pedal Position Jumper On Pedal Assembly Bracket Digital Transmission Range Sensor Left Side Of Transmission Inertia Fuel Shutoff Switch Behind Right Side Of Front Kick Panel Starter Relay Right Rear Of Engine Compartment NOTE: 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 before disconnecting battery. NOTE: Transmission Range Sensor Alignment Gauge (307-351) is required for this procedure. See Fig. 1 .

Fig. 1: Identifying Transmission Range Sensor Alignment Gauge (307 - 351) Courtesy of FORD MOTOR CO. Fig. 2: Aligning Digital Transmission Range Sensor (4R100) Courtesy of FORD MOTOR CO.

4R70W Transmission 1. Disconnect the battery ground cable. Raise and support vehicle. Disconnect the Digital Transmission Range (DTR) sensor electrical connector. See Fig. 3 . Do not pry on the swivel tube to disconnect the transmission shift linkage. Disconnect the manual lever shift control cable. Remove the manual control lever nut and discard. Remove the lever. 2. Loosen the DTR sensor bolts. Manual shift lever must be in the Neutral position. Using the Transmission Range Sensor Alignment Gauge (307-351), align the DTR sensor slots. See Fig. 4 . The tool is designed to fit snug. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . 3. Install and position the manual control lever. Install a NEW manual lever shaft outer nut and torque to specification. With the manual lever in overdrive connect the shift lever control cable. Install the DTR sensor electrical connector. Lower the vehicle. Connect the battery ground cable. Fig. 3: Identifying Digital Transmission Range Sensor Components (4R70W) Courtesy of FORD MOTOR CO. NOTE: When the battery is disconnect and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

Fig. 4: Aligning Digital Transmission Range Sensor (4R70W) Courtesy of FORD MOTOR CO. TROUBLE SHOOTING Verify customer compliant by operating starting system. Check battery for state of charge. Check cable connections at battery and starter motor. Ensure transmission is fully engaged in Park or Neutral, or clutch pedal is fully depressed. Check central junction box fuse No. 21 (15-amp). Check Gray fusible links, located at positive battery cable. On models equipped with anti-theft system, ensure anti-theft system is operating properly. See appropriate PASSIVE ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT for additional information. If problem is not found, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS. SYSTEM TESTS SYMPTOM INDEX Symptom Perform Test Engine Does Not Crank & Relay Clicks A Engine Does Not Crank & Relay Does Not Click B Engine Cranks Slowly C

TEST A: ENGINE DOES NOT CRANK & RELAY CLICKS 1. Verify battery condition. If battery is okay, measure voltage between each Red wire at starter motor relay and ground. Battery voltage should be present at one Red wire only. If battery voltage is present on one Red wire, go to next step. If battery voltage is not present on either Red wire, repair or replace Red wire between battery and starter motor relay cable. Check system operation. 2. Measure voltage between starter motor solenoid "B" terminal and ground. See Fig. 5 . If battery voltage is present, go to next step. If battery voltage is not present, clean and tighten battery and solenoid terminal connections. If battery voltage is still not present, replace positive battery cable. Check system operation. 3. Using jumper wire, connect one end to positive battery terminal and with other end, momentarily touch starter solenoid "S" terminal. See Fig. 5 . If solenoid engages, go to next step. If solenoid does not engage, replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Check system operation. 4. Using heavy gauge jumper wire, connect one end to positive battery terminal and with other end, momentarily touch starter solenoid "M" terminal. See Fig. 5 . If starter spins, go to next step. If starter does not spin, replace starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Check system operation. 5. Disconnect solenoid relay switch connectors. Disconnect starter motor solenoid connectors. Measure resistance of Red wire between starter motor relay and starter solenoid. If resistance is less than 5 ohms, replace starter motor relay. If resistance is 5 ohms or greater, repair or replace Red wire between starter relay and starter solenoid. Check system operation. Unusual Starter Noise D Starter Spins But Does Not Crank Engine (1) (1) Inspect starter motor mounting. Inspect flywheel ring gear and starter motor gear for damaged and missing teeth. Repair or replace components as necessary.

Fig. 5: Identifying Starter Solenoid Terminals (Typical) Courtesy of FORD MOTOR CO. TEST B: ENGINE DOES NOT CRANK & RELAY DOES NOT CLICK 1. Remove fuse No. 111 (40-amp) in battery junction box. Check continuity of fuse No. 111. If fuse No. 111 is okay, reinstall fuse and go to next step. If fuse No. 111 is open, install new fuse and go to step 15 . 2. Remove fuse No. 21 (15-amp) in central junction box. Check for continuity of fuse No. 21. If fuse No. 21 is okay, reinstall fuse and go to next step. If fuse No. 21 is open, install new fuse, and go to step 18 . 3. Measure voltage between ground and input side of central junction box fuse No. 21 while holding ignition switch in START position. If battery voltage is present, go to step 6 . If battery voltage is not present, go to next step. 4. Disconnect ignition switch 15-pin connector. Measure resistance in Red/Light Blue wire between input side of central junction box fuse No. 21 and ignition switch connector terminal STA. See Fig. 6 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Red/Light Blue wire between ignition switch and central junction box. See WIRING DIAGRAMS . Check system operation.

Fig. 6: Identifying Ignition Switch Connector Terminals Courtesy of FORD MOTOR CO. 5. Remove battery junction box fuse No. 111 (40-amp). Measure resistance of Light Green/Violet wire between ignition switch harness connector terminal B5 and output side of battery junction box fuse No. 111. See Fig. 6 . If resistance is less than 5 ohms, replace ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. If resistance is 5 ohms or greater, repair open in Light Green/Violet wire between ignition switch and battery junction box. See WIRING DIAGRAMS . Check system operation. 6. Turn ignition switch to LOCK position. Disconnect starter motor relay connector (Tan/Red wire). Measure voltage between ground and Tan/Red wire at starter motor relay connector terminal while holding ignition switch in START position. If battery voltage is present, replace starter motor relay. Check system operation. If battery voltage is not present, go to next step (A/T models) or go to step 12 (M/T models). 7. Disconnect Digital Transmission Range (DTR) sensor 12-pin connector. Measure resistance of Tan/Red wire between DTR sensor connector terminal No. 12 and starter motor relay connector. See Fig. 7 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Tan/Red wire between DTR sensor and starter motor relay. See WIRING DIAGRAMS . Check system operation.

Fig. 7: Identifying Digital Transmission Range Sensor Connector Terminals Courtesy of FORD MOTOR CO. 8. Check DTR sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR under ADJUSTMENTS. If DTR sensor is adjusted properly, go to next step. If DTR sensor is not adjusted properly, adjust as necessary. Check system operation. 9. Connect a jumper wire between DTR sensor connector terminals No. 12 (Tan/Red wire) and No. 10 (Dark Blue/Orange wire). See Fig. 7 . Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace DTR sensor. See DIGITAL TRANSMISSION RANGE SENSOR under REMOVAL & INSTALLATION. Check system operation. 10. Disconnect Clutch Pedal Position (CPP) jumper 6-pin connector. Measure resistance of Dark Blue/Orange wire between DTR connector terminal No. 10 and CPP jumper connector terminal No. 2. See Fig. 7 and Fig. 8 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or greater, repair open in Dark Blue/Orange wire between DTR sensor and CPP jumper. See WIRING DIAGRAMS . Check system operation.

Fig. 8: Identifying Clutch Pedal Position Switch Or Jumper Connector Terminals Courtesy of FORD MOTOR CO. 11. Measure resistance between CPP jumper terminals No. 1 and 2 (component side). If resistance is 5 ohms

or less, go to step 14 . If resistance is greater than 5 ohms, replace CPP jumper. Check system operation. 12. Disconnect starter motor relay connector (Tan/Red wire). Disconnect CPP switch 6-pin connector. Measure resistance between Tan/Red wire at starter motor relay connector terminal and CPP switch connector terminal No. 2 (Dark Blue/Orange wire). See Fig. 8 . If resistance is less than 5 ohms, reconnect starter motor relay and go to next step. If resistance is 5 ohms or greater, repair open in Tan/Red wire or Dark Blue/Orange wire between CPP switch and starter motor relay. See WIRING DIAGRAMS . Check system operation. 13. Connect a jumper wire between CPP switch connector terminals No. 5 (White/Pink wire) and No. 6 (Gray/Yellow wire). Connect another jumper wire between CPP switch connector terminals No. 1 (White/Pink wire) and No. 2 (Dark Blue/Orange wire). See Fig. 8 . Attempt to start vehicle. If vehicle does not start, go to next step. If vehicle starts, replace CPP switch. Check system operation. 14. Disconnect central junction box 34-pin connector C270b. Measure resistance of White/Pink wire between central junction box connector C270b terminal No. 29 and CPP switch/jumper connector terminal No. 1. See Fig. 8 and Fig. 9 . If resistance is less than 5 ohms, replace central junction box. If resistance is 5 ohms or greater, repair open in White/Pink wire between central junction box and CPP switch/jumper. Check system operation.

2000-2003 Ford F150 Pickup Truck Workshop Repair Service Manual BEST - 620MB !

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