I have a 2002 Ford F350 7.3L. The other day I had a hard start that required 10-15 minutes of holding the key to start. The starter finally dragged like I ran the batteries down. Now the truck will not turn over at all when the key is engaged. This is what I have done to troubleshoot the problem. 1) Had the batteries tested, and charged. Both appear to be good. 2) Removed the starter, had it tested. Showed bad, replaced it with a rebuilt starter. 3) Checked all fuses, none need replaced. Once the starter was replaced, I reinstalled the batteries fully charged. Truck will not turn over at all when the key is engaged. Could this be a relay issue? Thanks, Lee

 

If you were able to hold the key to start for 10-15 minutes your batteries are definitely good!

You may have gotten a bad starter. Many replacement starters are know to be bad out of the box, or fail shortly after install. Does the starter do anything when you crank it or does it act like nothing? If so it could be your relay. Sometimes the starters will spin fine under no load, but when you load it with a diesel engine compression, they do not have the torque in them to turn the engine over.

When you checked the fuses dis you do it with a test light or meter or did you just look by eye? You should make sure the fuel bowl heater fuse is good with a meter or test light.

Do you have a spare Cam Position Sensor? The original ones are known to fail and can cause a no start. Most 7.3L owners keep one in the glove box to keep that from happening. You can get one from the Ford dealer for around $30 to keep as a spare.

 

"Does the starter do anything when you crank it or does it act like nothing?"
Does nothing at all.

"If so it could be your relay."
Where is the relay located at?

"When you checked the fuses dis you do it with a test light or meter or did you just look by eye?"
Eye, but I will test with a light and verify.

"You should make sure the fuel bowl heater fuse is good with a meter or test light."
Where is this located at?

"Do you have a spare Cam Position Sensor?"
I don't, but I will pick one up asap.

 

If you held the key on for more that just a minute or so at a time, you may have burned you starter up. Should never hold it too long at a time without allowing it cool down. Also, check the wiring going to the starter soleniod. there is a fuseable link that will melt down if it gets too hot/

 

The relay is on the passenger fender.

Should be maxi fuse 111, This will not affect the cranking, just the starting.

 

Hold the key to start for 20 or 30 seconds and see if any of the battery cables get hot. Holding the starter on that long probably killed the old starter and it may have overheated your battery cables and caused a poor connection. Be sure and check the grounds too.

If none of the cables get warm while trying to start, shift into neutral and try again.

Ford got rid of the old fashioned fender mounted starter relay on the 02 model year so don't bother looking for that but do check your fuses and relays in the panel under the steering wheel.

 

Well now that I didn't know. Guess they got rid of the fuseable links as well?

 

Yea. The manual still says the relay is there but I checked my truck about a dozen times one day going back and forth from the manual to the truck. Finally traced the battery cable from the battery directly to the starter solenoid.

I had been planning on using the little wire on the relay as my kill switch on an upcoming trip and was disappointed to find out I didn't have one.

 

"Do you have a spare Cam Position Sensor?"

Could someone tell me where the Cam Position Sensor is located on the 7.3L?
I have a spare one to put in.

 

If u lay on the ground and look at the crank shaft pulley, it is in the 10 o'clock position next to it. It has one 10 mm bolt that holds it in.

 

It is located at the 10 o'clock position the lower pulley/balancer on the crankshaft. If you crawl under the front of the truck to the passenger side, look between the block and the belt. You should see something that looks like the picture below.

 

I want to thank all you who posted for your help. I have the truck running again with no current issues.


Here is what I found to be the problem.

1) when installing the new starter the small red connector lead broke. (now replaced)
2) no fusable link found between the batter and starter.
3) no starter relay found.
4) cam position sensor replaced, no known problems before except can shaft code P0603 was present.
5) cam sensor replaced, no codes currently present.

Thank you guys for your help!

 

Glad u got it going.

 

2002 trucks no longer have a remote starter relay at firewall.
The starter and solenoid are tied together at starter. There is still a starter relay under dash at main fuse center.
There seems to be a issue with the three bolt starters and the cheaper two bolt units offered up at the chain auto parts stores.
I am currently dealing with this same issue.

 

So I was reading all of your guy's post and I have a 2002 7.3l. When it's cold it's hard to start. It will start but I it's hard unless it's plug in. The same thing happened to my dads 2001 and he took it in and it was the relay. It cost him over $200 for the relay so I was thinking about doing it myself. Where is the relay located on the 2002 7.3? I read that they don't have it under the fender. Did they just do away with it? Some pictures would be nice if any of you have them. Sorry if this has been covered in another fourm. I'm new to this site.