Don't understand why my fix worked, but it did

74,200

Asked by OJ Jul 05, 2020 at 07:22 PM about the 1999 Ford Explorer 4 Dr XL SUV

Question type: Maintenance & Repair

4.0 OHV engine.  Began as an intermittent no start (crank but no fire).  
Finally would not start at all.  Started with starting fluid.  Would start, but
stumble, then smooth out.  Would start a couple of times after that, then no
start again.  Hooked up fuel pressure gauge, turned to on position and
pressure raised to 55 lbs.  No start.  The tach would not move at all in
cranking mode so I suspected crank position sensor.  Before climbing under
the truck I decided to swap out the horn relay with the fuel pump relay.  It
started right away without starting fluid like normal.  Did so about ten times
with no problem.  I am stumped as to why I was getting 60 lbs pressure with
old relay, but no start?  Then swapping out relay, it starts fine.  I also thought
the tach should bounce a little to indicate rpms while cranking if there is a no
start condition.  NOTE:  The fuel pump and horn relay, and two others are all
5 position relays, but I don't know of the b pin is used at all.  Could the crank
position sensor also be bad but not affecting start?  

4 Answers

74,200

Can someone explain why the fix worked? I don't like being confused.

1,835

I work roadside assistance and that is a common thing that happens, a relay in the same position running let's say the fuel pump, the contact points get a gray dust and burn marks etched into them over the years and no longer make good contact. When u switch it with one less used like the horn relay, the fuel pump will work. I do suggest u get a new relay for the horn... because when u do need it in an emergency situation it will act like the fuel pump and not work.

74,200

Thanks Peter, I already got a new relay for the fuel pump and put it in. My confusion centers around getting fuel pressure with the old relay (supposedly only for the pump) and a no start condition. Then inserting a new relay, I still get the same pressure in the on position, but a start condition.

1,835

The contacts in the old relay were probably not releasing or engaging where needed for a start condition.

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