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Discussion Starter #1
I have a 94 Mercury Cougar and I am having starting issues.

The other day on the way to work, I stopped to get some breakfast, came out and the car would not start. Just one click. I bumped it a few times, played with the stick positions and if finally kicked over. That was last Tuesday.

Last night I go to my mom's to fix her computer and when I went to leave, same issue, but this time it would not start.

I went back this morning and it bumped over first time and each time after that.

I stopped several places and the car started right up.

I get home, notice the temp is getting high but the fan is not coming on. It got up the H before I shut if off and still no fan. Then I tried to turn it over and same issue. I even let it cool down for several hours and it still won't turn over.

I ran KOEO and no codes showed up. I was not able to run the KOEO test I guess because the engine won't bump.

Pulled 12.36 vdc from the battery with the key off. My Town Car was at 12.02vdc! Sounds like the battery is fine. Also pulled the terminal connectors off and reseated them. They are clean with no corrosion.

Starter? Electrical?

What is weird is the fan never went on when it was getting hot, yet the KOEO test, I heard the fan go on low speed then hi speed.

Any suggestions would be appreciated.

Oh, I also ran the diags on the test connector according to my Snap-On Appendix guide and I have the corret voltages for the connector.
 

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Discussion Starter #2
It was the Neutral Safety Switch. As you may know it is right next to the exhaust pipe and as time goes on, the heat wears down the switch and it starts to crap out. So I replaced the switch with a good one I had on the shelf and this time PUT A HEAT SHIELD AROUND IT!

I have replaced the Neutral Safety Switch
1999 @ 58k, bought the car
2005 @ 108k, replaced switch
2009 @ 126k, replaced switch
2014 @ 138k, replaced switch

While I had the car up on jacks, I drained and replaced the engine oil and filter. I also drained and filled the transmission oil and replaced the filter. Before I torqued the pan bolts, I made a galvanized sheet metal shield that surrounds the switch and takes most of the heat before it gets to the switch (At least that's my theory). I still don't know why the fan was not running, it worked fine today. When I ran diags with the code reader, it showed an unknown error 632. Which means "Overdrive cancel switch not changing state " but my code reader did not tell me to turn off the O/D and turn it back on. So I will need to run the test again and see if that was all that the code meant. I say unknown cause my code reader only goes to 1993 and I have a 1994. The tranny was different that year so that makes sense the code was unknown.

Whatever it takes the keep the car running. Though I spotted a 2006 Cadillac DTS that had low miles and priced at a good price... :zpuke:

Hope you all had a good Memorial Day! :usa:
 
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