Hello All,

I have a 2004 Ford F-250 with the 6.0 egr has been deleted and so on. Truck has been very trustworthy until now... It all started last week. I would get in and it would fire right up, drive 15 miles to work all is still good. Time to go home try to start and it would act like the batteries were weak with a weak crank until it finally takes off and starts. This intermittent situation has been happening but I just assumed that the batteries were going bad. I drove to work this morning truck fired right up and now that it is time to go home the truck only has a weak crank and wont fire up. I tested the batteries and they were low on cranking amps. Replaced them with two new batteries. The issue still exists and didnt change. After reading through threads I found that it could be the FICM I checked it out as was shown through the other threads. With the key on only it was reading 51 vdc with someone trying to start the truck it was reading 48-50 vdc... Yes the truck does have fuel in it and yes the oil is good to. It seems that there is something electrical going on for sure due to the way it has been an intermittent problem for a week or so. Any info on this would greatly help. I am an aircraft mechanic by trade but can fix anything if I know where to start. All help is appreciated. Thanks.

 

Grounds...Grounds...Grounds....check and clean all of them from the batteries to the starter, even the smaller ones attached to the core support and inner fenders. You dont mention mileage?
Cleaned all the grounds and positive connections if problem persists have both batteries load tested(again). If they load test ok then have the starter bench tested. Hit it with a hammer the next time it does it. If it takes off the starters tired.
Check for voltage on both sides of the solenoid with the key turned toward start.
A battery cable can visually inspect ok yet have high resistance due to age and unseen corrosion. Ohm them out, they should have low resistance. And or do a voltage drop test. The drop test will pin-point the weak spot such as bad cables, connections, starter or solenoid.
Be aware that batteries can be bad right out of the box. same goes for any part.
Also be aware that those fits-alls generic battery cable ends are junk. Solder and shrink tube or replace the cable.

 

I will check it out and report back thanks for the input

 

Everything is good. Checked all grounds cleaned them and reinstalled. Batteries are good. Battery cables check out good. Starter checks out on both ends of the solenoid. I am at a complete loss. Any more ideas? Thanks

 

Thanks for all of the help I finally got it going. Turns out I didn't hit the starter hard enough. I got pissed off and really hit the sob and guess what my truck runs. Thanks a million

 

So its time for a new or rebuilt starter.
Clean the wire connections down at the new starter before you bolt it up. After its installed spray that area with either battery terminal spray or clear ignition sealer. I prefer the sealer on the starter and terminal protector on the battery terms.