OK, i have a 97 expy 4.6. Lately since its been cold she dont wanna start. When I hit the key I hear the relay on the firewalll pop or click but it dont crank. After about 20 times or so she'll start up. If i use my remote starter it will start up after 5 or 6 tries. I was told it might be a starter but i dont wanna replace the starter if its just a relay or something. The battery is prefect also. If anyone else has had this problem with their engine let me know what the soultion is.

Thanks
Mike

 

check the starter solenoid on the firewall i've seen a couple of those crap out and then work fine for a few times then crap out again. also check starter wires for corrosion at starter and solenoid. I checked it with a test light one big wire always has juice and when you turn key to start the other big wire should get juice.

also see if the teft light is flashing real fast when it wont start.

 

Being a 97, I don't think you have the fat security loaded key. You are probably dead on with the cold effecting the starter motor that is assuming it fires right up once the engine warms it.

 

Had exactly the same problem on my boy's '97 Expedition. Cranking the engine was intermittent. We took the starter off and found a bad weld joint INSIDE the solenoid where the wire is stake welded to the screw that comes through the case, onto which one of the little wires attach. I'm a little vague, it was a while ago. We cleaned it up, soldered it on good, and it has been working ever since.

Not saying this is your problem, as it was a little "off the wall". The big problem is around here - I couldn't find just the solenoid. Had to buy the starter and solenoid together. What a rip off. If I could have bought a solenoid for $50 I may not have messed with it. But $180 for both???? I fixed the old one.

Good luck. ... Dennis