E150 no start please help

[lngroller]

My 96 E150 with 5.8 is having problems. a month ago I replaced starter. everything fine. Now van won't start but I can jump the starter relay and start it. I replaced the relay. I can hear it engage (click) when I turn the key but nothing. (Old relay did not click) I can still start it by turning on key and jumping the relay.

Since the key turn makes the relay "click" I assume the ignition switch is fine. since I can jump the relay and start it, the starter and cables must be fine. I am looking for another cause then a bad relay, any suggestions or is the new relay just bad? I am 300 miles from home ( and where I purchased the relay) I had to leave on a business trip fixed or not and now feel like an idiot opening the hood and using my screwdriver to jump the relay at every stop. any comments welcome. If all else fails I will get a monentary contact switch and rund 2 wires from the relay to the switch and start it that way until I get home.

[jwalker1970]

How are you jumping the relay? A. Crossing 2 big posts together or B. Crossing small post with big post (battery side)?

My suggestions: Take a test light to the small (start) post of your relay. Does it light up when you turn the key? If Yes, then your relay is bad or it is not grounded properly. In this case It will NOT start when you cross small post to Battery side lug.

If you are getting no power on your small (start) terminal, then check for a power at your "start" wire at the ignition switch. If you have power there, check continuity between start wire at ignition and your starter relay.

Good luck.

Note: Some Fords had a firewall relay (solonoid) and another solonoid on the starter itself. The spade connection on the starters were notorious for becoming loose and not contacting. (probably not in your case, but maybe check for good measure)

[lngroller]

I jump it by crossing the 2 big posts. Since I am not home I don't have a multimeter with me but since I could hear the audable click at the starter relay when turning the key I ruled out the ignition wire. But don't know enough about the circuit to know if I did so prematurely. same with a bad ground on the relay. My assumption was if I jumped the 2 large terminals and it started it was grounded correctly. I am at a disadvantage of being on the road without all my tools and multimeter, repair manual, etc. I think your info will help me narrow it down for sure. Thanks!