Hey guys, I need some assistance here. I searched through the forums and couldn't find any sure answers.
Here's the deal. I went out this morning to start the truck and it would not start. I thought the battery was bad since it is the original from '97. I replaced that and still nothing. I am getting a 'single' click sound that is coming from the passenger side firewall. It is where the battery cables connect and split off in that box. Do you think it is a relay? Do you think it is the starter? I Don't here a clunk near the starter like I'm used to when a starter goes bad and you hear that pinion hit the flywheel.
We used the truck yesterday and it seemed fine...

 

The clunk you're hearing should be the starter solenoid relay, I think. It sends power to the solenoid on the starter. It's been my experience that the starter will start to stick when they are going bad. You can confirm this by lying under the truck and having someone turn the key, bump the starter with a wooden hammer handle or something solid. If starts to work go buy yourself a starter.

Now for the disclaimers: Lying under a vehicle while it is operating can be hazardous to your health. Think it through before you do it: trans in park or neutral, wheels chocked, parking brake set, and someone you really trust at the controls.

 

Go under the truck with a hammer, have someone crank it/ turn key to crank and whack on the starter. If it then starts- bad starter.

 

O.k guys I'll give that a shot in the morning. I was just out there in the driveway tinkering with it. I'll have to push it in the garage tomorrow and crank up the heater. It's about 20 degrees right now.....
Anyway, I was reading some info from a repair manual and they had me do some checks. They had me jump a hot wire to the ignition signal wire terminal on the relay. I got the same response so that ruled out ignition switch. I tried crossing the two posts on the terminal which did not work which rules out the relay. so it then says to see if there is power down at the starter...well it is parked on a puddle , it is 10:30 pm and COLD... so I'll go down there with a test light...a piece of wood and a hammer and give it a few cracks.....

The last starter I changed was on my 74 Chevelle...a few years ago. I have not paid too close attention to my F150's location. Is it pretty comparable? the manual does not state having to remove anything crazy..just the leads and then the starter motor. I know some times, exhaust pipes transmissions etc are in the way.... Is it a simple swap????

 

It took me about an hour to change mine. I wound up removing the right front wheel in order to easily access the bolts....one in particular. I also used a couple of extensions to reach one bolt. It's not as easy as some I have changed....but that's my opinion.

 

I had a similar problem 2 years ago with my 97 4.6. The starter was groggy which made me think dead battery. Since it was original, I replaced it. All was fine for two weeks until I go to start it one morning and nothing. Funny thing was that I jumped started it with another vehicle, took it to a Ford garage, and it was the starter. I only had 60,000 on it at the time.

 

I haven't had to change a starter since my '73 F250 several years ago so I don't know if the design is still the same. Ford used to be notorious for their 3 bolt starters. Last time I had to change one I needed about 3 feet of extension on the socket, other option was to lay across the air filter with a wrench and turn the bolt about 1/8 of a turn at a time.

 

I'm tellin ya, whack away at the starter, its somewhere down there by the transmission. Have someone turn the key, and whack it.

Usually its the starter, not the wiring, modules, or relays.

If you have a vat40 I could tell you in about 30 seconds if the starter is bad or not.... but generally only shops have them.

It could be a corroded battery cable or ground cable to and from the starter.... but its still probably the starter. whack away.

 

Voltage drop that bad boy!! Haha.... Check your voltage drop across the starter relay then across the starter itself. If the relay drops anything more then 1/2 a volt, it's going to be the relay. If the starter drops 12 volts then it's more then likely the starter.

 

I've changed a couple of these on 97&98 F150's, both had arounnd 100K miles on them. It's located on the right side of the engine at the rear where the bell housing and engine bolt together. Have yourself a good assortment of extensions and maybe a universal. I've never taken the front wheel off for easier access, but if you think it'll help, try it. Be carefull not to overtighten the nut that holds the power cable on. It can spin inside the starter housing and break the connection internally. This can make for a bad day when installing a shiny new starter. As mentioned above if whacking the starter doesn't help check the condition of the cable. Installing a new starter only to find that the cable is corroded inside the insulation can also make for a bad day. Good luck.

 

First off...thanks guys for all the input. I tried smaking it a few times but it did not start. So, I had to push it into the garage. It was hard to remove, most of the nuts bolts had corrosion and it was hard to figure out which size sockets to use. To make a long story short, it was the starter. I'm not sure if it is a positive cable or ground but it is a braided wire about 1/2" that goes from the solenoid into the starter(prob. negative). Anyway that corroded and there was a 1/4" of that braided wire just gone....
It made me feel better knowing I did not have to question it any longer. After the hassle so far, I'd hate it not to be the starter.

Now just some notes incase somebody stumbles on this thread in the future and needs help like myself.
It was so much easier to take off the front pass. tire like 'ddrumman2004' mentioned. I can't imagine being able to do it with out it off.
The small lead on the solenoid is an 8mm.
the larger leads are 13mm.
Definetly disconnect the wires first. It is so hard to get leverage on the nuts with the starter twisting and dangling.
there are 3 bolts that hold the starter on and they are 13 mm as well. The top is the hardest to see, the bottom bolt is basically a studd it holds the starter on and has additional threads for the ground wire to bolt to. My stud snapped off so I just connected the ground wire to the bottom bolt when I installed the new one.(sometimes you just gotta' make do)
The bolts are pretty tuff to break loose, definetly soak them ahead of time with WD-40.
You do need a universal (swivel) socket, and several various length extensions.
I have to say it was much easier to reinstall the new starter compared to removing the old one.
Thanks again guys ................