Ford Explorer starting problems?

You really ought to be near 14 volts for normal charging, even higher for a low battery. It may run as low as 12.6 in warm weather with a fully charged battery. Regardless of alternator output or even if it's broken if you charge up that battery it should start. If you're getting lights dimming or occasional start clicks or slow turns the neutral safety is probably not your trouble. Since you've had the battery and starter checked I'm guessing the trouble is with a wire or starting relay. Check for power at the input of the starter relay when the key is turned. (The small wire that feeds the coil of the relay, the big cable is what gets switched by it) If it's there all the "logic" of the system is working and the trouble is with the basics, battery, starter, wires. You ought to be able to hear this relay. If relay power is there, check for voltage on starter input. If it's not there either the relay is bad or there's a bad battery cable or connection. A poor cable or connection can actually drop some voltage across it and cause some very odd behavior. Don't ignore the negative cable(s).

Now if there's no voltage at the relay input all bets are off. Neutral switch or any number of sensors could be causing problems.

Was the starter tested under load? Simply applying power on the bench and making it spin doesn't mean it works when actually trying to turn an engine. Generally, if the starter is engaging but just can't turn the engine you should still see a voltage drop while trying, perhaps even more so than a healthy starter.

If you poke around with a volt meter at all the components involved I'm confident you can find the trouble.

Ford Explorer Starter Problems

there are too many sensors in that car its run by the computer, what the problem is off hand I dont know, I do know that there were a lot of problems with that car, go to car complaints.com and look up some of the complaints and recalls there may be information that can point you in the right direction but I believe scanning for codes and then going from there is your next option and a AAA card is a really good idea on cars 10 years of age or over. The good news for you is the 02 was a real lemon, over 7,000 complaints and counting, good luck even reading some complaints in other years may help but offhand I believe you are headed for a diagnostic from the shop, this will trouble shoot the problem hopefully and save you any more uneccessary disassembly.

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Check the ground cable, the 91-94 where bad for corroded cables, but the thing is it was hid by the insulation, so try taking a utility knife and cut back the insulation and see if there is white dust on the wire, if so then replace the ground cable, also to verifier this use jumper cables and go from the ground post to the block and see if it starts,

I have a 2001 ford explorer that is blowing the 50 amp fuse when I try to start ,I replaced starter and starter switch check battery cables to starter cant find any bad spots stilling blowing fuses

Unless you took the battery out and tested it on a LOAD tester, I would still suspect a weak battery.