Ford Ranger / B-Series :: Sudden No Start / Brief Low Chatter With Every Key Turn


Jun 25, 2012

2007 Ranger XLT 2.3, 55k miles

Went to start truck today and got very little response.

Symptoms:

Workee:

Dome light (regular brightness)
key in/door open chime

No workee:
Dash lights
Solenoid (no response)
Headlights
Radio
Turn signals
Hazard lights

VOM tested battery- 12.82 V
Cleaned battery terminals

Every key turn there is a brief low chatter from interior fuse box.
Occasionally dash lights will flash briefly on key turn.
Occasionally PATS dash light will flash in 2 second cycle.

I'm suspecting the ignition switch but the no headlight condition puzzles me.

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-Replaced coil (had it tested, failed primary test on terminal 1, and secondary on 3 and 4)
No change
-Checked Spark by grounding spark plug
Good
-Checked Fuel at rail
Good- Held until empty, primed Fuel system (key on for 3 seconds 5 times) checked again, good)
-Truck had been sitting for three months, so put in small bottle of stabil and added 5 gallons with Lucas. Primed the system about 20 times, and tried to start. No effect.
-Checked battery.
1 bad cell, 3 low on water- replaced battery. Allowed it to crank for longer (before we were jumping it) but still didn't want to.

Note of concern : After we replaced the battery and went to start it, when the key was disengaged I noticed a hissing sound coming from the radiator cap. The truck is in Upstate new york and hasn't been ran in 3 months. I'm hoping its not but thinking it is a cracked jacket or a blown head gasket.

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Battery tests good - 12.4 volts; connections appeared fairly corroded.

Here is what I have done:

- Clipped off the first half inch of corroded terminal leads, replaced both sides with new battery connectors and wire brushed connections off at battery and starter.
- Replaced Starter
- With "S" connector disconnected, attempted to bypass starter connections and short terminals to see if a faulty clutch position sensor was to blame; shorting did not produce anything other than turning the key did.
- Paralleled an additional cable from battery to starter terminal to see if corroded wire connections were to blame; still just clicked repeatedly when attempting to start.

Crankshaft does rotate manually, does not appear to be seized up. Unsure of what else to check for. Not confident in friend's engine installation abilities, he may have screwed up something I'm not thinking of. On the other hand, I don't believe I would have been capable of swapping out the motor myself.

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