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1997 F350, lately turn key and get a loud click, no crank. Do it a couple more times, and then it cranks and starts just fine. I replaced the starter relay and exact same thing still happening. Batteries at 12.48 volts, could that be the problem? Only does it when cold, never if I have driven it in the last 6 hours or so. Could be a red herring... Manual transmission, could the safety switch on the clutch be the issue? Any guesses out there?
Are your battery connections clean and tight? Also the starter/cable connection. Can you tell where the "click" is coming from, the fender relay or the starter? If all connections are clean and tight, and with the new fender relay, I would suspect the solenoid on the starter.
If you are getting a click in the engine compartment, the clutch safety switch is not the problem.
Hey man, thanks for taking the time to help. Battery connections all tight and clean. Click is coming from the starter relay on the fender. When I jump the posts it starts, but not right away -- kind of a sloppy process but maybe I am not making good contact with the posts. Could be the replacement switch I put in is not working well, but that is unlikely. Seems like your idea about the starter solenoid may be it, but I'd have to get all new starter wouldn't I, or can you replace just the solenoid? Also, could batteries at 12.48 volts be the problem? I know that is low, but doesn't seem that low...
Sounds just like when mine failed. Clicks, but does not send power to the starter solenoid.
Current path is roughly:
Crank signal from key to fender solenoid
Fender solenoid routes modest current to starter solenoid
Starter solenoid sends high current through starter motor
If fender solenoid "clicks" when key turned to crank, the ignition switch and safety circuits (clutch or park/neutral) are operating
If starter turns when fender solenoid is jumpered, then starter, starter solenoid, and connections to starter are at least kind of ok (still could have less-than-ideal starter/cables/connectors... but that's not your primary problem)
So that leaves the fender solenoid. I would not be surprised if the fender solenoid posts are gunked up, leading to weak current to the starter solenoid when you jumper it, and maybe the starter solenoid not getting a consistent, decisive "start" signal.
You can test the fender relay with a test light and a helper. Connect the lead of the test light to the negative post on the battery, and touch the post on the relay with one wire, and have the helper try to start the engine. If the relay just clicks and you get no light on the test light, the relay is bad. If yyou get a light , the problem is down stream, either the wire from the fender relay to the starter is damaged or the starter solenoid is bad. The solenoid on the starter can be replaced, depending on the type of starter you have.
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