Ford Repair: 98 Windstar wont start, negative battery cable, crank pulley


Question
QUESTION: I have a 98 Windstar that won't start. When I turn the key, it just clicks as the starter engages and tries to turn the engine, but the engine won't turn. The starter was broken where one of the bolts thread in, so I thought the starter might be binding up. I charged up the battery and installed a new starter and it just does the same thing with the new starter! I put a socket on the crank pulley and the engine turns just fine by hand. I also tried starting it in neutral and it just does the same thing. What could be causing this?

ANSWER: before i can come up with any thougts, i need you to try this. disconnect what is called an m.l.p. sensor. it is located in top of the transmission near where the shift lever connects to the trani. it is possible especially given the year that, that particular sensor is tryong to keep the torque converter engauged which won't let it start. or, run a hard heavy ground wire to your starter case and a hard positive wire to the starter and see if it kicks the starter over when the positive wire hits it. be careful of course but should this help, you had a bad cable ( positive ) to the starter. or a bad ground as the starter uses the engine as a ground. if this doesn't make sense. please get back to me and i'll try to explain a little better

-b-

---------- FOLLOW-UP ----------

QUESTION: Thanks for the help Brian. I went ahead and replaced the sensor with a new one. It still just clicks, just a lot quiter now. Before, when the starter engaged, it would rock the engine trying to turn it. Now, it just clicks quietly like there's not enough power to turn it over. The battery is reading 12.68 volts so it seems ok. I replaced the negative battery cable already too. Man, am I missing something?! I'm going nuts trying to figure this out. Any ideas?

P.S., I also pushed the van forward in drive about 15 to 20 feet and it rolled just fine so I don't think the transaxle or engine is frozen up.

Answer
if you have replaced the negative cable, and you know the battery is good and starter is new it only indicates two other possibilities. run a heavy gauge wire right from the battery positive terminal to the positive lead on the starter.  and turn the key this should turn the starter.  if this doesn't work, there should be a small wire attached to the starter that engauges the solenoid look at it cloaselt for corrosion. suggest cutting this wire back 6 inches and eplacing it try this and get back to me