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Well thought my batteries were toast. 2-1/2 year old red tops. Charged al day and night truck still wouldn't hit. Napa replaced for free, install new and still no go. So I'm thinking starter is toast. The lugs are rusted, but not corroded on the starter. Of course there is no one here to help with my volt meter either.
wow did you find that at the bottom of the ocean?
there is more rust in that picture than on all of my vehicles combined. (I am down to 6 now)
Truth^ I had a Scout II that sat in a field with no windows for 15 years with less rust than that.
IMO Todd splurge on a new one and be done with it. Day 2 of owning my 7.3 it wouldn't start. I didn't even check, I just replaced the batteries and the starter to be done with it. Worth it for the $150 and peace of mind.
Get a powermaster starter off of Ebay and never look back. I'm from MI, that picture doesn't surprise me. Seems like nine out of ten threads like this its always the starter at fault.
I was going to jump the relay, but won't the neutral safety switch override it?
Nope. Just make sure the truck isn't in gear when you jump it! My grandpa almost lost his leg that way once.
Turn the key to run, make sure it's out of gear and then jump the relay with a big screwdriver and see what happens. When it doesn't start, does it just crank slow or does it just click and not crank?
my starter was doing the same thing the other morning click, but no turnover. finally, very carefully as I was too lazy to disconnect the batteries, I put a wrench on the big lug on the starter (same as in your picture), and was able to turn it ~1/16 of a turn tighter. truck started right up after that.
...my terminals are corroded, but nothing like the rust in your pic!
if you don't care about being stranded someday, i'd say take all the wires off, wirebrush everything real good, and put it back on. it'll probably be OK for a while.
might want to also check the engine block grounds. my old truck had corroded grounds there. no other electrical problems, but it couldn't support the high current back through the starter-housing, through the block, to the batteries. cleaned them up and it was fine from then on.
Well the starter is bad. Got the truck bump started by pulling it with the Subaru, glad no one took a pic! Lol. This is the second starter in powerstrokes in as many weeks that has turned over but not fired the truck.