2001 F250 4WD 7.3 diesel. Recently, the start circuit fuse blew while trying to start. New fuse in, pop. Replaced the starter just because I felt like it was time. 210,000 miles. Life was good for a couple days, then pop goes the fuse. replaced the solenoid on the inner fender well, and guess what? Life was good for a few days, then pop goes the fuse again. Having some time to investigate today, I determined the issue is the wire going to the solenoid. Disclaimer: I am not an electrical engineer, but I did stay at a Holiday Inn Express last night. The starter will crank by jumping the posts on the solenoid, so I am calling everything good from there to the starter. I have installed a push button start to keep it running while I figure this bugger out. My question is, is/was there an issue within the start circuit that I can look for? The wiring from the solenoid appears to be in good condition, but I have not unraveled the tape enclosing it. As a side note, the wiring harness was resting on top of the turbo. I assume it may have gotten hot, but I see no signs of melting. I am developing a love/hate relationship with this POS......errrrr I mean this awesome truck. Any help would be appreciated!

 

Today I just finished a full primary cable upgrade on my tuck, made an adjustment yesterday most of the work was done.
There should not be any cables near the turbo. If you are talking about the bundle that is about one inch in diameter it should be attached along front of the cab under the window area with clips. If this was in fact the bundle that was resting on the turbo or close to it you do need to open it up and look at all the wires. You are likely to have other issues you have not found yet. If I remember correctly the wire that carries the signal to the start relay is in there. Find all the melted or burnt wires and patch them with new proper grade wires. Use Crimp fittings only as the heat and vibration from the truck will kill solder joints.
Use the good stuff. The repair job is not difficult. Do it once.

Yes you are going to need to take the bundle apart. When done use new wire loom and good tape to seal everything back up.It can get wet in that area do do it correctly.