Drove it last night around 9pm. Parked it and went to drive it again this morning around 7:30. No cold weather here or rain. Here is what I know:
When I turn the key I hear a click (not a repeating click) but the engine doesn't turn over. Batteries have 12.5 volts. I put my trickle charger on them and had full charge after about 3 or 4 minutes. When I turn the key the headlights do not go dim. I put a screw driver across the solenoid on the passenger side fender and got a strong arc. When I do that, I can also hear another click that sounds like its coming from the engine. I tapped the starter a few times with a hammer, but it still wont turn over. I'm guessing bad starter. Any suggestions?

 

If everything looks normal on the gauges, check fuse 30 under the dash. I believe 20 amp fuse and I'm pretty sure that's the right fuse number.

Is your fuel bowl heater plugged in? If so, and the fuse is blown, unplug the heater lead on the back and bottom of your fuel bowl, then replace the fuse. Hurts nothing to leave it unplugged (mine has been for quite a few years.)

Hope that's the cause. If not make sure all grounds and pos connections are clean and check voltage to starter with a dvm while someone keys it for you. If you have strong voltage, starter is prob shot.

Denny

 

Denny, it depends on what year truck. If it's a 2002-03 it's different than the 1999-01's.

 

2001 to be exact

 

Then I would check what Denny is saying, and go from there. It does sound like starter/solenoid issues, but if that fuel bowl heater fuse is blown, you will have a no-start issue. As he mentioned, you can replace that fuse and unplug the connector at the back of the bowl, short term. If you live anywhere where you see cold temps below 30 degrees or so, I would get a kit to replace it. It's pretty straight forward.

http://www.riffraffdiesel.com/fuel-bowl-heater-element/

 

I'll check it out, but I dont think it got much less than 60 yesterday. Its currently 70 now. We dont have temps below 30 very often and when we do its only a couple weeks out of the year.

 

Than you may not need to replace it. There are plenty of warm climate guys that don't. They just unhook it and go. IF that's your issue. Check it out and let us know.

 

What is different on the 02+ trucks that you were going to mention, as you can see mine is an 02 and I would like to know what to do if a situation arises.

Thanks!

 

The fuse was still good, unfortunately. I picked up a starter while I was in town yesterday just in case. I'm about to pull both batteries and trickle charge each one, then take them in for testing. Hopefully one of the problem lies there before I pull off the old starter. Here is a link to manual for a 2001 and the service guide for anyone interested:

http://www.fordservicecontent.com/Fo.../01f23og4e.pdf
http://www.fordservicecontent.com/Fo.../01nmgmg5e.pdf

If anyone has any other suggestions on things I can check I'd be glad to check them! Thanks!

 

So after I took both batteries off the truck and charged them, it fired right up. I'm talking easy. May still go get my batteries, alternator, and starter checked.

I was getting like 12.7-12.8 volts on one battery when they were off after charge and like 13.1 on the other. With them on and the truck running I'm getting 13.65 volts across both batteries. With the truck off and both batteries mounted im getting 13.1 across one, and now 13.05 across the other.

I believe my truck has 2 alternators, is 13.65 volts enough to charge the batteries? Could one alternator be bad? Both batteries took charge, so I would assume they are good. Or is my starter system playing tricks on me?

 

13.55 on the back terminal of the top alternator to ground, while getting 13.49 across the batteries. I can figure out where to test the bottom alternator at.

 

Took it for a spin. 13.55 on the alternator to ground, 13.5 across each battery after driving with the truck still running. Turned the truck off and checked each battery with the cables off. 12.9 on one, and 12.7 on the other.

 

Took the batteries out and had them tested at advanced. I know the rule of thumb is replace them at the same time. My batteries are mismatched. I pulled them out the truck a few minutes ago outside temp was around 60 and temp in store was probably 70 plus:

EverStart rated at 750 cold cranking amps: 12.77 Volt, 726 CCA measured, 160 deg F
Napa Legend rated at 1035 cold cranking amps: 12.77 Volt, 1053 CCA measured, 160 deg F

According to advance, both batteries are "good"

 

after checking the batteries at advance I figured i'd check the alternators. since the bottom is hard to get to, I started with the top. I unplugged it and now I'm only getting 12.5 volts with the truck running. I think its safe to say the bottom alternator is bad and the likely culprit. The reason my truck was probably not starting was the batteries were not charged up due to the bottom alternator not working

 

Sorry I didn't respond until now.There is a timing thing with the PCM and the bottom alternator. I wouldn't go by just that reading you got.