2000 Econoline starter problem

My 2000 econoline e150 with 102k miles is having starting issues in the cold. It starts fine when warm, or the engine is warm. When engine cools to freezing and I try to start, I hear a click. Door locks are not sluggish, headlights are bright and the blower sounds fast and I keep the van connected to a battery tender so I believe I have a charged battery. I keep turning the ignition and eventually the starter will engage, and the engine will sputter a bit and then run fine.

I did a forum search and haven't come up with a situation that matches this. Is it the starter or the solenoid? Could it be something else that I have not considered?

I keep the van connected to a battery tender so I believe I have a charged battery.
Without testing your battery, you are assuming it is good.

Check voltage at the battery when cranking. You may have enough to run the accessories but not enough to start. How old is your battery? Cables clean and tight?

The battery is <6 months old. That is the reason I use a tender now. Repeated lack of use killed the last battery.

I think I have found the reason. I believe that there is moistire inside the starter that is freezing and preventing the armature from engaging the flywheel. Repeatedly turning the ignition switch to the start position eventually works it loose and it cranks the engine. When the moisture is above freezing, such as when weather is more accomidating or the engine raises to operating temperature, it operates without fail.

Overall, I believe that replacement of the starter is the appropriate solution.

The battery is <6 months old. That is the reason I use a tender now. Repeated lack of use killed the last battery.

I think I have found the reason. I believe that there is moistire inside the starter that is freezing and preventing the armature from engaging the flywheel. Repeatedly turning the ignition switch to the start position eventually works it loose and it cranks the engine.


When it won't crank do you just get a click as if nothing is turning, or do get a whirrrr as if the starter is turning and not engaging the flywheel?

Just a single click for every turn of the key. When things work loose, it starts without issue.

That's good. If you would be getting a whirrr, I would be warning you to replace the starter immediately so you wouldn't grind the teeth off the flywheel in one spot and have a bigger repair on your hands.

If I was to guess at your problem, I would say the solenoid on top of the starter or the relay. A little testing with a multi-meter or test light may help you narrow it down. Also check what aleekat said. Good luck.

Without proper voltmeter testing, you are just guessing.

When it won't crank do you just get a click as if nothing is turning, or do get a whirrrr as if the starter is turning and not engaging the flywheel?
They sell amp meters you lay on the cable and you can check how many amps the starter is drawing. Use your volt meter and check battery voltage then watch what is happening as you try to crank. A battery can show full voltage and drop when a load is placed on the battery.