Ford F150 Pickup. Instruction — part 693

1. Ensure battery is fully charged. Disconnect the inertia fuel shutoff switch located behind right front kick

panel. Connect remote starter switch between starter solenoid terminal "S" and positive battery post.
Connect positive DVOM lead to positive battery post, and negative lead to solenoid terminal "M". See
Fig. 11 .

2. Engage remote starter switch. DVOM should indicate .5 volt or less. If DVOM indicates .5 volt or less,

go to STARTER GROUND CIRCUIT TEST . If DVOM indicates greater than .5 volt, go to next step.

3. Move negative DVOM lead to solenoid terminal "B". Engage remote starter switch. If DVOM indicates

less than .5 volt, solenoid connections or contacts are bad. Clean solenoid terminals "B", "S" and "M".
Repeat steps 1 -3 .

4. If DVOM still indicates greater than .5 volt at terminal "M" and less than .5 volt at terminal "B", solenoid

contacts are bad. Replace starter motor. See STARTER MOTOR under REMOVAL &
INSTALLATION. If DVOM indicates greater than .5 volt at terminal "B", clean cables and connections
at solenoid.

5. If DVOM still indicates greater than .5 volt at terminal "B", check for poor positive battery cable

connection or bad cable. Repair as necessary.

NOTE:

Make all DVOM connections at component terminal rather than at cable or wire
end.

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup

Fig. 11: Testing Voltage Drop
Courtesy of FORD MOTOR CO.

STARTER GROUND CIRCUIT TEST

1. Disconnect the inertia fuel shutoff switch located behind right front kick panel. Connect remote starter

switch between starter solenoid terminal "S" and positive battery post. Connect positive DVOM lead to
starter housing, and negative lead to negative battery post. See Fig. 12 .

2. Engage remote starter switch while observing DVOM. The DVOM should indicate .2 volt or less. If

DVOM indicates greater than .2 volt, clean negative cable connections at battery and engine and retest.

NOTE:

Make all DVOM connections at component terminal rather than at cable or wire
end.

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup

3. If voltage drop is still excessive, repair or replace negative battery cable and/or engine ground cable as

necessary. Repeat starter ground circuit test after repair to ensure problem has been corrected.

4. If battery and cables test okay and starter motor still cranks slowly or not at all, replace starter motor. See

STARTER MOTOR under REMOVAL & INSTALLATION.

Fig. 12: Testing Starter Ground Circuit
Courtesy of FORD MOTOR CO.

BENCH TESTING

STARTER DRIVE TEST

1. 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. 5 . Verify starter drive ejects. Remove positive
lead from starter motor. Starter drive should return to original position. If starter drive does not eject and
return to original position, install new starter motor.

2. Check starter drive. It should turn freely in one direction, and positively engage to armature when rotated

in opposite direction. If starter drive does not move as specified, replace starter motor.

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup

STARTER NO-LOAD TEST

1. Remove starter motor. See STARTER MOTOR under REMOVAL & INSTALLATION. Place starter

motor securely in a vise. Connect remote starter switch between positive battery terminal and starter
motor "S" terminal. See Fig. 5 . Connect starter motor "B" terminal to positive battery post. Connect
starter tester with DVOM and ammeter, according to tool manufacturer's instructions.

2. Ensure starter motor is grounded. Engage remote starter switch. Starter should eject starter drive and turn

smoothly and quietly. DVOM should indicate 11 volts or more, and ammeter should indicate 70 amps or
less. If voltage is lower or current is higher than specification, or unusual noise is present, install new
starter motor.

REMOVAL & INSTALLATION

CLUTCH PEDAL POSITION (CPP) SWITCH

Removal & Installation

Disconnect the Clutch Pedal Position (CPP) switch electrical connector. See Fig. 13 . Pull down on CPP switch
retaining clip and slide CPP switch toward driver seat. Remove the plastic retainer by pushing the lock tabs
together and sliding the plastic retainer off the CPP switch. See Fig. 14 . Remove CPP switch from clutch pedal
rod and remove CPP switch. To install, reverse the removal procedure.

NOTE:

Make all DVOM connections at component terminal rather than at cable or wire
end.

CAUTION: 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.

2003 Ford Pickup F150

2003 STARTING & CHARGING SYSTEMS Starters - F150 Pickup