2003 FORD EXPLORER 4.6 starter solenoid /relay location and removal?

The starter solenoid relay is located in the starter assembly itself.This is part of starter system only.If it fails the starter as a whole has to be replaced.

The solenoid and relay are integral with the starter.

Removal & Installation

Relay Switch

CAUTION

When performing maintenance on the starting system be aware that heavy gauge leads are connected directly to the battery. Make sure protective caps are in place.

1. Disconnect the battery ground cable.
2. Remove the protective cover.
3. Disconnect the push-on electrical connector (2).
4. Remove the nuts (3).
5. Remove the cable (4).
   
   
   

   

   Fig. Starter relay switch-4.6L engine

6. Remove the engine sensor/alternator wires.
7. Remove the mounting bolts and ground wire.
8. Remove the starter motor solenoid relay switch.

To install:

1. Installation is the reverse of removal.

Tightening torques:

Mounting bolts 44-97 inch lbs. (5-11 Nm)

Nuts (3) 44-97 inch lbs. (5-11 Nm)

The starter removal and installation:---------

Removal & Installation

1. Disconnect the negative battery cable.
2. Properly raise and support the vehicle.
   
   
   

   

   Fig. Disconnect all wires connected to the starter, including this ground wire on the starter mounting bolt stud

3. Tag and disconnect the wiring at the starter.
   
   WARNING

   When detaching the hard-shell connector at the S-terminal, grasp the plastic shell to pull it off. Do not pull on the wire itself. Ensure to pull the connector straight off to prevent damage to the connector and S-terminal. If any part of the connector is damaged, replace the damaged component.
   
   
   
   
   

   

   Fig. Some starters use a self-threading bolt to hold the starter cable

   
   
   
   

   

   Fig. Remove the starter motor (arrow) mounting bolts . . .

4. Remove the starter mounting bolts and remove the starter.
   
   
   

   

   Fig. . . . then remove the starter-be careful, the starter motor can be quite heavy

To install:

1. Position the starter motor against the engine and install the mounting bolts. Tighten the mounting bolts to 15-19 ft. lbs. (21-27 Nm).
2. Install the starter solenoid connector by pushing it straight on. Ensure that the connector locks in position with a notable click.

Install the starter cable nut to the starter solenoid B-terminal. Tighten the nut to 80-123 inch lbs. (9-14 Nm).

1. Connect any remaining wiring to the starter motor.
2. Lower the vehicle.
3. Connect the negative battery cable.

1. With the vehicle in NEUTRAL, raise vehicle on hoist.
2. Disconnect the battery ground cable.
3. On 2005 Sport-Trac, remove the frame damper.
4. Remove the starter solenoid terminal cover.
5. Remove the nut and disconnect the starter solenoid battery cable.
6. Remove the nut and disconnect the starter solenoid wire.
7. Remove the 3 starter motor bolts and the starter motor.
   
   
   

   

   Fig. Showing the frame damper .

   
   
   
   

   

   Fig. Starter assembly shown in mounting position-4.0L engine

   
   
   
   

   

   Fig. Starter assembly shown in mounting position-4.6L engine

To install:

1. Position the starter and install and tighten the starter motor bolts to 18 ft. lbs. (25 Nm).
2. Install the solenoid wire and tighten the nut to 44 inch lbs. (6 Nm).
3. Install the solenoid wire and nut. Tighten the nut to 10 ft. lbs. (13 Nm).
4. Install the solenoid terminal cover.
5. If removed, install the frame damper. Tighten the bolts to 18 ft. lbs. (24 Nm).
6. Connect the battery ground cable.

Testing & Troubleshooting

Feed Circuit Test

1. Make sure the battery is fully charged.
2. Disconnect the inertia fuel shutoff switch (IFS switch). Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
3. Connect a Digital Multimeter (DMM) positive lead to the battery positive (+) post. Connect the negative lead to the starter solenoid M-terminal.
4. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volts or less.
5. If the voltage reading is 0.5 volts or less, go to the -Starter Ground Circuit Test- below.
6. If the voltage reading is greater than 0.5 volts, indicating excessive resistance, move the DMM negative lead to the starter solenoid B-terminal and repeat the test.
7. If the voltage reading at the B-terminal is lower than 0.5 volts, the concern is either in the connections at the starter solenoid or in the solenoid contacts.
   
   
   

   

   Fig. Starter motor feed circuit

8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals.
9. Repeat Steps 3 through 6.
10. If the voltage drop reading is still greater than 0.5 volts when checked at the M-terminal and less than 0.5 volts when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
11. If the voltage reading taken at the solenoid B-terminal is still greater than 0.5 volts after cleaning the cables and connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself.
12. By moving the DMM negative lead toward the battery and checking each mechanical connection point, the excessive voltage drop can be located. When the high reading disappears, the last mechanical point that was checked is the concern. Repair or install a new connection as required.

Ground Circuit Test

A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit.

1. Disconnect the inertia fuel shutoff switch.
2. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
3. Connect the Digital Multimeter (DMM) positive lead to the starter motor housing (the connection must be clean). Connect the negative lead to the negative (-) battery terminal.
4. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.2 volts or less.
5. If the voltage drop is more than 0.2 volts, clean the negative cable connections at the battery and body connections, and retest.
6. If the voltage drop is greater than 0.2 volts, connect the DMM positive lead to the end of the cable nearest battery positive.
7. Connect the multimeter negative lead to the terminal at the other end of the cable.
8. Crank the engine and observe the voltage reading. The voltage reading should be 0.2 volts or lower. If the voltage drop is too high, clean the terminal ends.
9. Retest, and if still high, install a new cable. If the voltage reading is less than 0.2 volts and the engine still cranks slowly, install a new starter motor.
   
   
   

   

   Fig. Starter ground circuit