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For 1990-2009 cars only

Starter Solenoid Does Not Click 7.2L

Step

Action

Yes

No

Schematic Reference: Starting and Charging Schematics

1

Did you perform the Diagnostic System Check - Vehicle?

Go to Step 2

Go to Diagnostic System Check - Vehicle

2

Turn the ignition switch to the START position.

Does the engine crank?

Go to Testing for Intermittent Conditions and Poor Connections

Go to Step 3

3

Turn the ignition switch to the START position.

Does the starter motor relay click?

Go to Step 7

Go to Step 4

4

  1. Remove the starter motor relay.
  2. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to ground.
  3. With the transmission in Park, Neutral, or the clutch pedal depressed, turn the ignition switch to the START position.

Does the test light illuminate?

Go to Step 5

Go to Step 6

5

  1. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to the control circuit of the starter motor relay coil circuit.
  2. With the transmission in Park, Neutral, or the clutch pedal depressed, turn the ignition switch to the START position.

Does the test light illuminate?

Go to Step 13

Go to Step 10

6

Is the starter equipped with over crank protection (OCP) thermal switch?

Go to Step 7

Go to Step 8

7

  1. Turn OFF the ignition.
  2. Disconnect the starter terminal switch.
  3. Turn ON the ignition, with the engine OFF.
  4. Connect a 10-amp fused jumper between the starter motor relay coil control circuits of the starter terminal switch.
  5. With the transmission in Park, Neutral, or the clutch pedal depressed, turn the ignition switch to the START position.

Does the test lamp illuminate?

Go to Step 18

Go to Step 8

8

  1. Turn OFF the ignition.
  2. Disconnect the park neutral position (PNP) switch. Refer to Park/Neutral Position and Backup Lamp Switch Replacement or Clutch Pedal Position Switch Replacement for the clutch/starter interlock switch.
  3. Turn ON the ignition, with the engine OFF.
  4. Connect a 10-amp fused jumper between the starter motor relay coil control circuits of the PNP switch, neutral switch, or clutch/starter interlock switch.
  5. With the transmission in Park, Neutral, or the clutch pedal depressed, turn the ignition switch to the START position.

Does the test lamp illuminate?

Go to Step 16

Go to Step 13

9

  1. Turn OFF the ignition.
  2. Disconnect the starter motor relay.
  3. Connect a test lamp between the battery positive voltage circuit of the starter motor relay switch circuit and a good ground.

Does the test lamp illuminate?

Go to Step 10

Go to Step 19

10

Connect a 30-amp fused jumper between the battery positive voltage circuit of the starter motor relay switch circuit and the supply voltage circuit of the starter solenoid.

Does the engine crank?

Go to Step 15

Go to Step 11

11

Does the fuse in the jumper open?

Go to Step 20

Go to Step 14

12

Test the control circuit of the starter motor relay for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 21

13

Test the supply voltage circuit of the starter motor relay coil circuit for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 17

14

Test the supply voltage circuit of the starter solenoid for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 18

15

Inspect for poor connections at the starter motor relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 21

16

    • If equipped with an automatic transmission, inspect for poor connection at the PNP switch, neutral switch (Allison) for the automatic transmissions harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . If OK, perform the Park/Neutral Position and Backup Lamp Switch Adjustment .
    • If equipped with a manual transmission, inspect for poor connection at the clutch/starter interlock switch harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 22

17

Inspect for poor connections at the ignition switch harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 23

18

Inspect for poor connections at the starter thermal switch/solenoid. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 25

Go to Step 24

19

Repair the open or high resistance in the battery positive voltage circuit of the starter motor relay switch circuit. Refer to Wiring Repairs .

Did you complete the repair?

Go to Step 25

--

20

Repair the short to ground in the supply voltage circuit of the starter solenoid. Refer to Wiring Repairs .

Did you complete the repair?

Go to Step 25

--

21

Replace the starter motor relay. Refer to Relay Replacement .

Did you complete the replacement?

Go to Step 25

--

22

Replace the following switches:

    • The PNP switch--Refer to Park/Neutral Position and Backup Lamp Switch Replacement .
    • The clutch/starter interlock switch--Refer to Clutch Pedal Position Switch Replacement .

Did you complete the replacement?

Go to Step 25

--

23

Replace the ignition switch. Refer to Ignition and Start Switch Replacement .

Did you complete the replacement?

Go to Step 25

--

24

Replace the starter. Refer to Starter Motor Replacement .

Did you complete the replacement?

Go to Step 25

--

25

Operate the system for which the symptom occurred.

Did you correct the condition?

System OK

Go to Step 2

Starter Solenoid Does Not Click 8.1/6.6L/7.8L

Step

Action

Yes

No

Schematic Reference: Starting and Charging Schematics

1

Did you preform the Diagnostic System Check - Vehicle?

Go to Step 2

Go to Diagnostic System Check - Vehicle

2

Turn the ignition switch to the START position.

Does the engine crank?

Go to Testing for Intermittent Conditions and Poor Connections

Go to Step 3

3

Turn the ignition switch to the START position.

Does the starter motor relay click?

Go to Step 11

Go to Step 4

4

Is the vehicle equipped with a manual transmission?

Go to Step 5

Go to Step 7

5

  1. Install a scan tool.
  2. Turn ON the ignition, with the engine OFF.
  3. With a scan tool, observe the Clutch Start Switch Signal parameter in the powertrain control module (PCM) / engine control module (ECM) data list while depressing the clutch pedal.

Does the scan tool display Released/Applied?

Go to Step 7

Go to Step 6

6

  1. Turn OFF the ignition.
  2. Disconnect the PCM / ECM harness connector.
  3. Connect a test lamp between the Clutch Start Switch Signal of the PCM harness and a good ground.
  4. Turn the ignition to the START position while depressing the clutch pedal.

Does the test lamp illuminate?

Go to Step 7

Go to Step 8

7

  1. Turn OFF the ignition.
  2. Disconnect the PCM / ECM harness connector.
  3. Connect a test lamp between the crank voltage circuit (starter enable relay control) of the PCM / ECM harness and a good ground.
  4. Turn the ignition to the START position.

Does the test lamp illuminate?

Go to Step 19

Go to Step 8

8

  1. Remove the starter motor relay.
  2. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to ground.
  3. With the transmission in Park, or clutch pedal depressed, turn the ignition switch to the START position.

Does the test light illuminate?

Go to Step 9

Go to Step 10

9

  1. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to the control circuit of the starter motor relay coil circuit.
  2. With the transmission in Park, or clutch pedal depressed, turn the ignition switch to the START position.

Does the test light illuminate?

Go to Step 17

Go to Step 14

10

  1. Turn OFF the ignition.
  2. Disconnect the park neutral position (PNP) switch Park/Neutral Position and Backup Lamp Switch Replacement or Clutch Pedal Position Switch Replacement .
  3. Turn ON the ignition, with the engine OFF.
  4. Connect a 10-amp fused jumper between the starter motor relay coil control circuits of the PNP switch or clutch pedal position switch.
  5. With the transmission in Park, or clutch pedal depressed, turn the ignition switch to the START position.

Does the test lamp illuminate?

Go to Step 18

Go to Step 15

11

  1. Turn OFF the ignition.
  2. Disconnect the starter motor relay.
  3. Connect a test lamp between the battery positive voltage circuit of the starter motor relay switch circuit and a good ground.

Does the test lamp illuminate?

Go to Step 12

Go to Step 23

12

Connect a 30-amp fused jumper between the battery positive voltage circuit of the starter motor relay switch circuit and the supply voltage circuit of the starter solenoid.

Does the engine crank?

Go to Step 17

Go to Step 13

13

Does the fuse in the jumper open?

Go to Step 24

Go to Step 16

14

Test the control circuit of the starter motor relay for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 25

15

Test the supply voltage circuit of the starter motor relay coil circuit for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 21

16

Test the supply voltage circuit of the starter solenoid for an open or high resistance. Refer to Circuit Testing and Wiring Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 22

17

Inspect for poor connections at the starter motor relay. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 25

18

Inspect for poor connections as follows:

    • If equipped with an automatic transmission, inspect for poor connection at the PNP switch harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs If OK, perform the Park/Neutral Position and Backup Lamp Switch Adjustment .
    • If equipped with a manual transmission, inspect for poor connection at the clutch pedal position switch harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs

Did you find and correct the condition?

Go to Step 29

Go to Step 26

19

Inspect for poor connections at the harness connector of the PCM/ECM. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 20

20

Replace the PCM/ECM. Refer to Control Module References for replacement, setup, and programming.

Is action complete?

Go to Step 29

--

21

Inspect for poor connections at the ignition switch harness connector. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 27

22

Inspect for poor connections at the starter solenoid. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs .

Did you find and correct the condition?

Go to Step 29

Go to Step 28

23

Repair the open or high resistance in the battery positive voltage circuit of the Starter Motor relay switch circuit. Refer to Wiring Repairs .

Did you complete the repair?

Go to Step 29

--

24

Repair the short to ground in the supply voltage circuit of the starter solenoid. Refer to Wiring Repairs .

Did you complete the repair?

Go to Step 29

--

25

Replace the Starter Relay. Refer to Relay Replacement .

Did you complete the replacement?

Go to Step 29

--

26

  1. Replace the PNP switch. Refer to Park/Neutral Position and Backup Lamp Switch Adjustment .
  2. Replace the clutch pedal position switch. Refer to Clutch Pedal Position Switch Replacement .

Did you complete the replacement?

Go to Step 29

--

27

Replace the ignition switch. Refer to Ignition and Start Switch Replacement .

Did you complete the replacement?

Go to Step 29

--

28

Replace the starter. Refer to Starter Motor Replacement .

Did you complete the replacement?

Go to Step 29

--

29

Operate the system for which the symptom occurred.

Did you correct the condition?

System OK

Go to Step 2