SOURCE: 2002 ford explorer wont start even after new battery...
Before you go changing out the starter check for a burnt out fusible link going to the starter it will look like a wire but acts as a fuse and they burn in two just like a fuse. The symptoms you just describe are those of a burnt fusible link.
SOURCE: my ford f150 wont start, battery is good, have a
On the firewall is the starter motor relay. There are 2 large battery sized cables to it, and 1 smaller ( 16 AWG ) wire that is orange or orange with a stripe ( forget the color, want to say white or tan ).
When you turn the key to the start position, check the smaller gauge wire for +12 V. The case should be ground. If you do not get +12 on the orange wire, try starting the truck in neutral ( apply the parking brake, chock the wheel, etc normal safety precautions ). Test for +12 V at the small wire. This is the output of the DTR ( Digital Transmission Range ) sensor or in common terms the Neutral switch. The start position on the ign switch runs through the DTR to the starter motor relay coil.
If you have a stick, the DTR is replaced by the Clutch Pedal Position Switch ( clutch must be pushed in to start ).
If you have power to this ( at the times the truck won't start ) next is to check the both battery cable ends to see if they are corroded and making intermittent contact ( not probable but possible ).
SOURCE: My 1990 Ford F250 won't start but has new starter, battery and ignition switch
Have you checked for 12 volts coming in going out of the the starter solenoid switch that is mounted passenger side fenderwell.
Testimonial: "No but that is logical; thanks! You can start the truck by 'jumping out' that same solenoid."
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