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All good, thanks. The PowerMaster was like $220 on Amazon I paid $330 for the Denso. After I posted I remembered I had a friend who owns his own Auto shop and he did highly recommend sticking with Denso. Not guaranteed on the skills of the person rebuilding the other kinds (if they are re-manufactured.) Not saying the others are not good, just a matter of choice for me.
Ok, finally got the Denso from CNC fab, installed. No cutting of frame necessary but a lot of finagling. The starting is better but still kind of a long crank before she fires up. I have two new batteries and new GPR. Maybe glowplugs going bad?
Probably the glow plugs. If they are original I would just replace them before winter hits. Make sure to use the Motorcraft ones. Sounds like you covered all the other bases.
Check to see that your earth straps from engine to frame are good. Poor earthing is the cause of many gremlins.
The negative cable from engine block directly to negative battery post is what should be inspected / improved. The vehicle frame doesn't add any benefit or value to the starting current path, only more resistance. And routing the high starting current through the frame can cause issues other low current modules grounded to the body and/or frame.
I took it to the shop and they said it was dropping 1.5V when starting. they checked the cables and said there was corrosion. They replaced the battery cables and now it starts like a champ, almost instantly! Thanks everyone for your input!
The negative cable from engine block directly to negative battery post is what should be inspected / improved. The vehicle frame doesn't add any benefit or value to the starting current path, only more resistance. And routing the high starting current through the frame can cause issues other low current modules grounded to the body and/or frame.
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