I replaced my starter on my '96 PSD yesterday. After replacing 2 batteries, glow plugs and wiring harness the truck was still hard to start in the colder weather. Fortunately my cousin let me use his heated garage. The top bold was a real pain in the ###. I loosened the 3 17mm bolts before I disconnected the wires. The large wire was also a tough one to remove. The little wire had to be cut and an eyelet was replaced. The little nut was completely rounded. The new starter spins really fast. I may try to see if it starts OK without the truck being plugged in. I used a reman starter from Advance since I needed to change it ASAP before the cold weather really sets in.

 

Did you verify that the GPR is functioning properly?

 

I did replace the GPR with one that I bought from Ford. Today when the temp was 25 the starter turned over quickly.

 

Are you using a de-gel fuel additive like Diesel 911?

 

Does it start properly with the new GPR?