Hello fellow ford owners. I purchased a 1996 Ford F350 7.3 diesel. Everything was just fine untill it wouldn't start. I replaced the solenoid and still nothing. I replaced the starter with a rebuilt Autozone starter. I replaced the key switch.The truck started up as expected 1 time. The next time I tried to start it, the same thing, it wouldn't start. Batteries fully charged. I checked grounding straps. OK defective starter. Went and replaced the starter with another rebuilt AutoZone starter. I did this another three times. Each starter would work one time. One starter melted a hole in the aluminium cap. It was very hot after a hour. It was suggested that I should go with another parts store. So I went to NAPA and bought a brand new Mitsubishi. This new starter started the diesel about 10 times and today it will not start. Solenoid doesn't make a sound nor the starter when turning on the key switch. Just nothing, Everything else works except it won't start. I'm 69 years young and want to take this truck along with a slide-in popup camper across America. Until I figure out my problem I'm leery to take the truck anywhere. Any suggestions would be appreciated. Thanks

 

My ignition switch actuator gave me some hit and miss starts before it finally broke completely in the driveway. Make sure the actuator, if equipped, has full thrust to the ignition switch.

 

Batteries, batteries, batteries ... have you had them load tested?

 

Thank for your help. The batteries are 1 year old and have had a load tested. When I pull the used (broken) starter out and replace it with another new or rebuilt it'll start every time. ONCE

 

"Solenoid doesn't make a sound nor the starter when turning on the key switch."

Try jumping the big terminals on the solenoid on passenger fender

If it cranks then maybe its the solenoid or the ignition switch is faulty

 

Knottyrope, Thanks for responding. I've jumped across the solenoid and nothing. If I replace the starter , it'll crank. One Time. I put another starter in it'll start one time I'm working on starter #6. AutoZone checked the starters as I brought them back for warranty. Some checked out good, some bad. I'm totally lost

 

Do you keep power to the accessories after the one start on the starter? If not, you might want to take a look at the battery grounds, both the posts and where they fasten to the engine block. They need to be shiney and tight. Are the battery cables in good shape?

 

Here is a pic on my 97 starter relay on the fender. Kinda hard to see but the rear terminal only has the big wire going down to the starter, nothing else. Make sure you purchased the correct relay as the unplugged wire is the ignition switched to energize the relay, it goes to plus 12 volts when cranking.

 

Up at the solenoid, disconnect the big wire to the starter. The one from the solenoid to the starter. Charge up your batteries overnight.

It would help if you have an electric meter to read 12V. Your batteries should hold more than 12.6 volts when fully charged. Better if they are near 13V.

With that big wire disconnected you should hear the solenoid clunk when you turn the key to the start position. When the solenoid clunks you have battery voltage at the lug where the starter wire connects.

It sounds like you have something hooked up wrong or got some bad parts besides bad starters.