Hows it going guys, I'm new here and posting this to try to help out my roommate who is having some issues with his van.

It's a 1997 E350 with the 6.8L. The problem we're having is that sometimes its starts just fine, cranks and fires right up, and other times it falls flat on its face like it has a dead battery (wants to crank but can't). The problem is very random and the no start symptom can occur, then start fine 10 minutes later. What usually happens is that it starts ok at the house, drive it somewhere, and doesn't start after it's shut off even it it only sits for 5 minutes with everything off. The battery was bench tested to be fine and shows good voltage on the gauge, and jumping it with my truck does absolutely nothing. I've considered it being either a grounding issue (we will replace the cables this week hopefully), alternator (voltage regulator?), or something stuck open somewhere not allowing voltage to get where it needs to go. Again, it starts great randomly, so I've ruled out starter issues (has a new starter) and starter solenoid issues (can still hear it click). Thanks for any input, ideas or similar experiences with a solution

 

check the voltage while cranking and when it won't.
That will tell the story. Could be a bad starter.

 

Good idea I'll have to get the voltmeter out tomorrow and see what it reads. Might be a really drained battery but the random start ups have really stumped me on this one.

 

Also did some research on the alternator fusible link and regulator, so that will get checked out at some point this week as well

 

you said the battery was bench tested. By who and how?

before you replace parts , see if it is charging and what the voltage is while the motor is running.