I got the transmission/engine back together and the flywheel is turning freely now. My new problem is - when I go to jump the starter solenoid nothing happens. I tried it 3 or 4 times, only got one "click" but otherwise nothing.

Here's the troubleshooting I've done...
- Cab lights all come on with ignition to on. (red battery light comes on after I attempt to crank)
- Batteries both read near 13v.
- Starter solenoid, reads 13v when bridged.
- Starter itself, reads 13v when bridged.

Any ideas?

The only thing I could think of was that the voltage was reading correctly, but it didn't have enough amps to do anything. I had both batteries on a BatteryTender, but they might have sat for a month before I thought to put them on.

 

When you try to start how low does the voltage go. Sounds like solenoid is bad or not grounded good. Have the batteries load tested.

 

Pull all 4 battery terminals off and clean them. A bad connection will cause this over and over - you might have only one small conductive spot, which is enough to give you lights and such. Try to crank, and it just burns out.

 

It barely drops, maybe half a volt or so.

 

I use a BatteryTender but they can be deceptive, they are basically a wallwart, maybe 3/4 of an amp tops. They will maintain a fully charged battery, but will choke trying to charge if the battery is real low. The reason is they incorporate protection circuitry to prevent boiling the battery for days at a time trying to get it to 100%, so they automagically switch to float after about 6 hours.

Can check battery state of charge by turning the headlights on for about ten minutes. Then wait at least ten minutes before measuring across battery post. Maintenance free batteries read 12.80 volts at 77° when 100% charged. Make sure they are charged then load test.

 

I took them by the local Auto Parts store and they tested them. Everything checked out OK.

I guess my next thing will be to clean everything off thoroughly and see if I have any better luck.

 

You can bench test your starter on the ground too. Just a quick check of everything.

 

What is clicking? The RELAY (on the fender) or the SOLENOID (on the starter)? Does the engine turn by hand?

 

Figured it out!

The previous owner had stripped the threads off the ignition terminal on the starter - so when I was underneath there tightening everything up I *thought* I had it all snug, but the wire was actually just hanging there. Occasionally, if the wire moved it made contact for a brief second and gave me a clunk. That explains why 3 of the 4 times I got nothing.

Regardless, I used my rethread kit to get enough on there that the bolt tightened down and....... drumroll.... after a couple attempts to get the fuel primed up, the truck starts now!

Thanks for all the help and suggestions guys!!!