Starter Page 1

Electrical
2001 STARTING & CHARGING SYSTEMS
Starters - Excursion & F250-F550 Super Duty Pickups
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), Clutch Pedal Position (CPP) switch (M/T), starter motor relay, and interconnecting cables
and wires.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
ADJUSTMENTS
DIGITAL TRANSMISSION RANGE SENSOR
1. Raise and support vehicle. Disconnect manual shift control cable from Digital Transmission Range
(DTR) sensor control lever. Disconnect DTR sensor harness connector. Place DTR sensor control lever in
Neutral. Loosen DTR sensor bolts.
2. Using DTR Sensor Alignment Tool (T97L-70010-A), align DTR sensor slots. Tighten DTR sensor bolts
to specification. See TORQUE SPECIFICATIONS . Place DTR sensor control lever in Overdrive and
connect shift lever control cable. Connect DTR harness connector.
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 (A/T). Ensure
clutch pedal to be pressed down completely (M/T). On Excursion, check maxi-fuse No. 116 (50-amp) in battery
j
unction box. On all other models, check maxi-fuse No. 20 (50-amp) in battery junction box. On all models
check fuse No. 20 (15-amp) in central junction box. If problem is found, repair as necessary. If problem is not
found, repair by symptom. See SYMPTOM INDEX
under SYSTEM TESTS.
ON-
V
EHICLE TESTING
NOTE: This article also applies to Cab & Chassis.
Component Location
Battery Junction Box Left Side Of Engine Compartment
Central Junction Box Under Left Side Of Instrument Panel
Digital Transmission Range Sensor Left Side Of Transmission
Inertia Fuel Shutoff Switch Behind Passenger's Side Kick Panel
Starter Motor Relay Right Rear Of Engine Compartment
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Starters - Excursion & F250-F550 Super Duty Pickups
2001 Ford Pickup F350 Super Duty
2001 STARTING & CHARGING SYSTEMS Starters - Excursion & F250-F550 Super Duty Pickups
Helpmelearn
November-29-07 6:28:15 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Helpmelearn
November-29-07 6:28:18 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Contents Summary of Starter

  • Page 12001 STARTING & CHARGING SYSTEMS Starters - Excursion & F250-F550 Super Duty Pickups DESCRIPTION NOTE: This article also applies to Cab & Chassis. The starter motor is a permanent magnet, gear reduction, 12-volt DC motor, equipped with an integral solenoid. Starting system consists of a starter moto
  • Page 2CAUTION: 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. Before testing starter,
  • Page 3Fig. 1: Testing Voltage Drop Courtesy of FORD MOTOR CO. STARTER GROUND CIRCUIT TEST NOTE: Make all DVOM connections at component terminal rather than at cable or wire end. 1. On gasoline engines disconnect ignition coil connector from ignition coil. On diesel engines, disconnect inertia fuel shutoff
  • Page 4ground cable connections at front cover and engine mount bracket. 3. If voltage drop is still excessive, repair or replace negative battery cable and/or engine ground cable as necessary. Repeat starter circuit test after repair to ensure problem has been corrected. 4. If battery and cables test okay
  • Page 5CAUTION: 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. CAUTION: Before testing
  • Page 6TRANSMISSION RANGE SENSOR under ADJUSTMENTS. If adjustment is okay, replace DTR sensor. Check system operation. If adjustment is needed, adjust as necessary. Check system operation. 7. Disconnect Clutch Pedal Position (CPP) switch harness connector. Measure voltage between CPP switch connector termi
  • Page 7Fig. 4: Digital Transmission Range Sensor Connector Terminals Courtesy of FORD MOTOR CO. TEST B: ENGINE DOES NOT CRANK & RELAY CLICKS (GASOLINE) 1. Measure voltage between Red cable at starter motor relay and ground. If battery voltage is present, go to next step. If battery voltage is not present,
  • Page 8solenoid does not engage, replace starter. See STARTER MOTOR under REMOVAL & INSTALLATION. Check system operation. 4. Using a heavy gauge jumper wire, connect one end to positive battery terminal and with other end, momentarily touch starter solenoid "M" terminal. See Fig. 3 . If starter spins, go t
  • Page 9Fig. 5: Identifying Ignition Switch Connector Terminals Courtesy of FORD MOTOR CO. 5. On F250-F550 Super Duty Pickups, remove fuse No. 20 (50-amp) from battery junction box. On Excursion, remove fuse No. 116 (50-amp) from battery junction box. On all models, measure resistance of Light Green/Purple
  • Page 10operation. 8. Perform DTR sensor adjustment. See DIGITAL TRANSMISSION RANGE SENSOR under ADJUSTMENTS. If DTR sensor is adjusted properly, go to next step. If DTR requires adjustment, adjust as necessary. Check system operation. 9. Restore all connections except DTR sensor. Connect a jumper wire betw
  • Page 11Fig. 6: Identifying Clutch Pedal Position Switch Or Jumper Connector Terminals Courtesy of FORD MOTOR CO. 11. Measure resistance between CPP jumper terminals No. 1 and No. 2 (component side). If resistance is less
  • Page 12than 5 ohms, go to step 14 . If resistance is greater than 5 ohms, replace CPP jumper. Check system operation. 12. Disconnect starter motor relay connector. Disconnect CPP switch 6-pin connector. Measure resistance in Dark Blue/Orange wire between starter motor relay connector terminal and CPP switc
  • Page 13WIRING DIAGRAMS . Check system operation. 23. Disconnect starter motor relay connectors. Measure resistance between CPP switch connector terminal No. 2 (Dark Blue/Orange wire) and ground. If resistance is greater than 10 k/ohms, replace CPP switch. Check system operation. If resistance is less than
  • Page 141. Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Secure motor in vise. Using fully charged battery, connect negative battery terminal to starter motor case. Momentarily connect positive battery terminal to "S" terminal. See Fig. 3 . Verify starter drive ejects. Remove positiv
  • Page 15SPECIFICATIONS . STARTER MOTOR SOLENOID RELAY - PICKUP CHASSIS Removal & Installation 1. Disconnect negative battery cable. Remove relay cover. Remove engine control sensor wiring. Remove nuts and cables. Remove starter motor solenoid relay switch bolts and switch. 2. To install, reverse removal pro
  • Page 16Diesel Normal Load 230-630 Amps No Load 170 Amps Starter Circuit Voltage Drop .5 Volt TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Starter Ground Cable Nut (Diesel) 13-17 (18-23) Starter Motor Mounting Bolts 17-20 (23-28) INCH Lbs. (N.m) Digital Transmission Range (DTR) Sen
  • Page 17
  • Page 18Fig. 8: Starter System Wiring Diagram (Excursion
  • Page 19
  • Page 20Fig. 9: Starter System Wiring Diagram (F250-F550 Super Duty Pickups