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Almost a grand later, no change. All new battery cables both pos and neg, flywheel has been checked good, 3rd starter installed, brand new batts. Has never started better... BUT.. Got it back yesterday, figured if it would behave this morning at 20 degrees it was good to go. Let the plug light go out, hit the key, sounded like gears grinding again. Got out of it, hit it again, and fired before it turned all the way over. So now it starts easy, but starter still grinds on first try in cold weather. Voltage drop checks are good as well. Does this when bypassing the relay/key switch with the connected by the blower motor as well. Any other ideas? I'm all tapped out.
Almost a grand later, no change. All new battery cables both pos and neg, flywheel has been checked good, 3rd starter installed, brand new batts. Has never started better... BUT.. Got it back yesterday, figured if it would behave this morning at 20 degrees it was good to go. Let the plug light go out, hit the key, sounded like gears grinding again. Got out of it, hit it again, and fired before it turned all the way over. So now it starts easy, but starter still grinds on first try in cold weather. Voltage drop checks are good as well. Does this when bypassing the relay/key switch with the connected by the blower motor as well. Any other ideas? I'm all tapped out.
I am not shure this is applicable to your situation but make shure the starter is mounting correctly.
A slight misalignment can cause the bendix to engage the flywheel incorrectly.
Some rebuilders also do not change the bendix at all if it looks good to the eye.
You may of initially had a failing starter. Now, with the reoccurring grind, you may have damaged teeth on the flywheel leading you to believe it's another bad starter. Next time you have the starter out I'd inspect the teeth for damage.
What is the actual positive cable like going to the starter? Can you do a voltage drop on it? Also points above are all good to rule out as well.
Brand new ford cables, brand new 1000/900 cca batts, flywheel inspected by myself and mechanic to have no issues. Flywheel wouldn't be dependent on temperature either I don't believe. I'm going to put an Oreilly's starter in it next time it rains and see what I get. Plugging in will prevent the issue, but truck will crank like it's summer down to around zero once you get the starter engaged and plugging in is not necessary nor always practical.
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