How to Replace the Starter Motor Relay in a Ford Taurusby eHow Cars Editor
If your 2002 Ford Taurus won't start, the malfunction may come from the starter motor relay, which helps to regulate current to, as its name suggests, the starter motor. Although easy to remove and replace, you should take extra care during repair as the starter motor relay rests in the engine compartment power distribution box--a fuse/relay box connected to high current wires.
Disconnect the battery. Remember, if you don't disconnect the battery you run the risk of an accidental electrical surge that could hurt you or cause costly damage to your vehicle.
Unlatch the cover of the power distribution box and push up. You don't need to remove the entire lid, as it can rest vertical to the box while you work.
Unplug your Ford Taurus starter motor relay from its socket located toward the back of the box (#23 block on your power distribution box diagram). This relay, one of the first two maxi-sized relay blocks that you can see as you look toward the back of the box, sits to the right of another relay block (#24 fan relay). If you're still uncertain of the location or for other model year locations, confirm using one of the owner manual .pdf files found at Ford Fleet (see Resources).
Check the box area for dirt, corrosion or damage that could cause the relay to malfunction. Clean, fix or repair any area, as needed.
Plug in your new relay and make certain the relay fits securely within its socket, as current running through a loose relay can cause the relay to overheat or the outer casing and surrounding relay casings/box cover to melt.
Push your power distribution cover down until it locks firmly into place. Reconnect the battery and start your Ford Taurus to test the new relay.
- close Never remove the power distribution box cover before disconnecting the battery, as you increase the chance of electrical shock.