The truck won't start with the key. I turn it to start, bam, starter relay fuse blows. I turn it to run and jump it over at the solenoid, starts right up. The solenoid is brand new, starter tests perfect, no bare wires from battery to solenoid to starter. Any one have any ideas??????
Try the following:
Verify that the fuse that is blown is the proper rating.
Replace the blown fuse with a good fuse with the proper rating.
Disconnect the small red connector from the terminal on the relay.
Turn the ignition key to the START position.
If the fuse does not blow, the problem is in the relay.
If the fuse blows again, the problem is most likely in the ignition switch.
The ignition switch may be miss-adjusted with respect to the key position, or the ignition switch may be at fault.
To check for miss-adjusted ignition switch;
Make sure that the small red connector on the relay is properly reconnected. Very slowly turn the ignition switch to the start position. Note whether or not the engines tries to start. Stop turning the key as soon as the engine tries to start. If it does try to start, this pretty much proves that the ignition switch is miss-adjusted.