The starter relay on the 1996 Ford Ranger with the V-6 and 4 cylinder engines are located in the engine compartment, mounted on the left-hand fender skirt near the battery. The purpose of the starter relay is to send high amperage from the vehicle battery directly to the starter motor. This allows the wiring from the ignition switch to be a much smaller gauge. The voltage from the ignition switch sends a signal to the relay, activating an electromagnet that pulls the high-amperage contacts closed inside the relay. Replacing the relay is a relatively simple task.
Disconnect the negative battery cable with a combination wrench, and wrap the end of the cable with electrical tape to prevent the cable from making contact with the battery while working with the relay. This will prevent the possibility of shorting the positive wires to any ground, which could cause damage to the solid-state electronics.
Using a combination wrench, remove the nut securing the positive battery cable to the relay. There could be more cables attached to this connection feeding other electrical circuits on the vehicle. To keep track of the wires, take a simple twist tie to secure all of the cables together. With a combination wrench, remove the cable going to the starter motor at the relay , then unplug the small gauge wire. This wire is coming from the ignition switch and just pulls straight off.
Using the ratchet, extension, and socket, remove the two bolts securing the relay to the fender skirt, then remove the starter relay. The mounting location is the relay's grounding point, so a clean and secure mounting site is essential for proper operation. You should be mounting to a clean metal surface with no corrosion or debris. Also, ensure that the mounting holes are not oversized. If the holes have become enlarged, you have two choices: drilling two new holes and relocating the relay just to the right or left of the old location, or use larger bolts to secure the relay.
Secure the new relay to the fender skirt, using the ratchet, extension and socket, and torque the bolts to between 45 and 85 inch-pounds with the torque wrench. Before attaching the cables and wires to the relay, inspect for any corrosion or broken wire strands. Clean the connections or replace the cables or wires as necessary. Attach the cable going to the starter, then the cables for the battery side of the relay, and torque the attaching nuts to between 70 and 130 inch-pounds with the torque wrench, socket set and extension. Attach the signal wire from the ignition switch to the small connection on the relay.
Remove the electrical tape from the negative battery cable end and inspect it for any signs of corrosion or broken wire strands. Clean or replace the cable as needed. Attach the cable to the battery and tighten the clamp with a combination wrench. Start the vehicle several time to insure proper starter operation.
