Ford Falcon XK 1960-1962 Starter Trouble Diagnosis Guide

The starter system in the Ford Falcon XK is responsible for cranking the engine fast enough for it to start. When the starter system fails to operate correctly, the engine may not crank, may crank slowly, or the starter may spin without turning the engine.

If the engine cranks normally but will not start, the fault is usually located in the fuel system or ignition system, rather than the starting system.

However, if the engine does not crank, diagnosis should begin with the starting system and associated electrical circuits.

When diagnosing starter problems, always confirm the issue originates from the starter system and not from other components such as the engine, transmission or driveline.

Engine Will Not Crank and Starter Relay Does Not Click

If the engine will not crank and the starter relay does not click when the ignition switch is operated, the problem is usually located within the starter control circuit.

Possible causes include:

Discharged battery
Faulty starter relay
Defective ignition switch
Open or high resistance wiring in the starter circuit

Check Battery Condition

Perform a battery capacity test to determine the state of charge.

If the battery fails the test, recharge it and repeat the test. Replace the battery if it is worn out or has insufficient capacity.

Check Starter Relay

With a fully charged battery, attempt to crank the engine.

If the engine does not crank and the relay does not click, disconnect and ground the high-tension lead from the ignition coil so the engine cannot start during testing.

Then connect a jumper lead from the battery terminal of the relay to the ignition switch terminal of the relay.

If the engine does not crank during this test, the starter relay is likely defective.

On vehicles equipped with automatic transmission, the neutral safety switch circuit should also be inspected.

If the engine cranks when bypassing the neutral switch circuit, the neutral switch may be misadjusted or defective.

If the engine still does not crank, inspect the wiring between the relay, ignition switch and fuse block for loose or broken connections.

Engine Will Not Crank but Starter Relay Clicks

If the relay clicks when the ignition switch is operated but the engine does not crank, the high-current circuit between the relay and starter motor should be inspected.

Connect a heavy jumper wire between the relay battery terminal and the starter motor terminal.

If the engine cranks during this test, the relay is faulty and should be replaced.

If the engine still does not crank, inspect the battery cables and ground connections.

Check Cables and Connections

Poor electrical connections can prevent sufficient current from reaching the starter motor.

Inspect:

Battery cables for corrosion or broken conductors
Ground cable connections
Starter motor cable connections

Clean and tighten all electrical connections. Replace any damaged cables.

If the engine still does not crank after these checks, the starter motor itself is likely defective.

Check Engine and Starter Drive

If the starter receives full electrical current but the engine still does not crank, further mechanical inspection is required.

If the engine cranks when the spark plugs are removed, water may have entered the cylinders and caused hydrostatic lock. In this case the cylinder heads must be removed and the source of coolant leakage repaired.

If the engine cannot be rotated by the starter motor, attempt to move the vehicle slightly with the transmission in high gear to free a locked starter pinion.

If the starter drive mechanism is locked, remove the starter and inspect the pinion gear and flywheel ring gear for worn or damaged teeth.

Starter Spins but Does Not Crank the Engine

If the starter motor spins but does not rotate the engine, the starter drive mechanism is usually worn or broken.

Repair or replace the starter drive components as required.

Engine Cranks Slowly

Slow cranking can be caused by several conditions including:

Low battery charge
Excessive resistance in the starter circuit
Faulty starter motor
Excessive engine friction

Check Battery

Test the battery to determine its state of charge.

If the battery is discharged, recharge it and inspect the starter relay for internal shorts that may have caused the discharge.

Replace the battery if it is worn out or unable to maintain proper charge.

Check External Circuit Voltage Drop

If the battery is fully charged, check the voltage drop across the starting circuit.

The voltage drop should fall within normal limits. Excessive voltage drop indicates high resistance in the electrical circuit.

Possible causes include:

Loose battery-to-starter relay cable
Excessive resistance at starter relay contacts
Loose relay-to-starter motor cable
Poor battery ground cable connection

Clean and tighten all connections and replace any cables with excessive resistance.

Check Starter Current Draw

If the voltage drop is normal, measure the starter current draw while the engine is cranking.

Normal cranking current is approximately 155–199 amperes.

If the current draw is low, remove the starter motor and repair or replace it.

If the current draw is normal or high but the engine still cranks slowly, excessive engine friction may be present and the engine should be inspected.

Safety Notice

Vehicles equipped with automatic transmission should not be pushed or towed for more than 12 miles without raising the rear wheels or disconnecting the driveshaft, as damage to the transmission may occur.

Safety, Copyright and Source Notice

Safety Disclaimer
Working on motor vehicles involves mechanical, electrical and chemical hazards. Always ensure the vehicle is safely supported, the engine is switched off when appropriate, and suitable safety equipment such as gloves and eye protection are used. If you are unsure about any repair or maintenance procedure, consult a qualified mechanic before attempting the work.

Source
Information compiled from period factory service literature.

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