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2006 Ranger 4.0 Starter Replacement

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Old 08-26-2018
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2006 Ranger 4.0 Starter Replacement

Hi All,
Never posted here before but since Ive go so much help in the past i figured Id add a post here to start repaying a bit.

I walked out to my truck to take it to the dump one morning. Turned the key and got just one click from the starter and thats it....wouldnt turn over.
I tried the simple stuff first..jump start, check the leads and grounds...everything looked OK.
Went underneath and saw that the starter flange was actually cracked right in front of the top bolt.
Here is how I fixed it...

Truck is a 2006 Ranger XLT 4X4 Auto trans.
190k Miles.

Starter has two bolts holding it to the tranny and three wires connecting it to the electrical system.
Bottom bolt is easy to get to.
It s a 13mm half bolt half post.
First nut holds the ground wire to the starter housing.
After that is off, use a 13mm deep socket to remove the bolt.
I used some PB blaster and a torch on the tranny to get it off without too much effort.

Top bolt is the tough one...barley reachable from the bottom, cant really get to it from the side.
I remvoed the driver side tire and the shroud that covers the side of the engine.
Then used a 13mm flex socket with about 18in extension on it to get to the bolt.
I threaded it in from the top left side of the opening over to the bolt.
I had to use a good amount of heat and PB Blaster to get it off.

Then onto the the remaining two electrical connectors.
There really is no way to get to it other than the way I did.
The wires that run from the battery to the starter are held away from the motor with two cable routing holds.
I removed the wire from the two holds then that gave me enough slack to get the starter out and drop it down enough to remove the wires.
Took a little pulling and turning but I got it.
13mm for the large nut and 10mm for the small one.

Be careful with the torch, fuel lines are 6 inches away to the left!!!

Install was the exact reverse.
New starter came with the small wire pre attached and instructions that said Ford had a service bulletin.
Had to cut off the last few inches of the existing small connector (ignition wire) and use the crip connector to put it back together.
Came with the crimp connector and shrink wrap on it already.
Used a lighter to shrink it.

Getting it off took me 3 hours or so.
Install was about an hour.

Make sure to disconnect the battery before you do any of this!

If anyone can think of anything I should add here please let me know.
Thanks for all the help everyone!

Cheers
Doug
 
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