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Hey everyone. Last night I jumped in my truck (1995 F-250 7.3 Powerstroke, 240,000 miles) and it would only click. Batteries had plenty of power so we crawled under and tapped on the starter with a hammer while someone else was turning the key and it started. I feel sure its the starter but is there anything else it could possibly be?
Also if it is the starter, how hard is it to drop it down and change it? Just looking at it, it doesn't look too bad.
That sounds like you got it...the armature in the starter is more than likely burnt up and a new or re-built one should fix you right up. As for changing it I do not know because I have never worked on that specific motor. Just unplug the battery and go at it.
There is a starter relay mounted on the pass side inner fender, towards the firewall a little from the battery. These sometimes fail. A good test is to jump the two large terminals on it with a screwdriver or wrench, if the starter then runs the relay may be bad.
However loose/dirty battery connections or burnt/corroded battery wires or loose battery ground wire to the engine could all be suspects.
Also check the wiring connections at the starter, the lighter gauge wire there can come loose.