FORD STARTER PROBLEMS
Ford Motor Company has issued two different Technical Bulletins relating to starting problems on 1992 and up cars and light duty trucks equipped with Permanent Magnet starters. Ford Motor Company’s TSB #94-18-3 and TSB #94-26-3 both discuss the no-crank or intermittent no-crank condition that exists when there is corrosion at the S-terminal of the solenoid. The solenoid wire is also listed as a problem, often corroding inside the wire covering. The Ford Motor Company offers a wiring connector assembly (Part # F4VY-14A411A) to repair the problem.

Dixie Electric is also offering a wire repair kit ( Part #79502-091 ). The 8” repair kit includes the proper “lock-on” OEM connector, with a crimp and/or solder connector on the opposite end. Heat-sink tubing is also included.

Correctly installed kit Locked connector on the Solenoid Switch Terminal

Dixie Electric Ltd. STRONGLY recommends performing a “voltage drop test “ between the connection at the starter solenoid “S” terminal and approximately 12” back into the wire harness. Use this Repair Harness when a problem is found.