03 f250 7.3L 185,000 miles

new starter, not a reman starter.
new battery cables, including grounds

I have been fighting the "no start" issue but now it is a "restart" issue. This last time I was towing the RV (30 foot Work and Play) and had to stop for fuel, I was at a truck stop and the starter would not engage. In the past I have been treating this like a "dead spot" on the started, my wife would try the key while I banged on it with a hammer until she engaged.

Well, Fast Forward and I have (several) new starters and ran new battery cables, have not had an issue until this time. I could not hear diesel trucks running in the bays next to me, so unsure if there was the click on the starter throwing out the gear. But I will say this time it was like the starter got hot and would not engage. I say this as it has started like 10 or so time since this failure. I did not see a thermal in the started to to support my theory. Any idea is there is one? It was like 109 outside and we ran for 3 full hours before stopping for fuel

I am thinking the "trigger wire" could be the culprit, since I have not replaced it. Maybe I should look there? Not Sure where the other end it, any great ideas or has anyone else had this become an issue?

 

What can you tell us about the starter in there now? How old is it?

 

new starter, less than 6 months old. I was getting reman but this a a new one and NOT a reman.

NAPA starter

On a side note: I followed the wire (yellow with a blue stripe) back from the starter. It goes up to the a large harness near the fire wall. There is a quick disconnect there, I am thinking about running a new wire from the disconnect to the starter.

 

Not sure if it’s auto or manual. If auto mess with the gear shifter while holding the key in the start position. Manual mess with the clutch pedal in and out.
I chased what I thought was an alarm no start issue with batteries and alarm wires only to find my neutral safety switch was defective causing my issue the entire time. Just a thought. Best of luck, Rye

 

What Rye said plus the range selector connector and if it's manual then the clutch pedal switch is in play.

 

it is an automatic trans

in the past, when I had the starter fail, I was able to get it going but hitting the starter. The neutral safety switch would likely NOT be the the cause of this.

But next time I will leave the key int he start position and run the shifter around to see if she fires. I have done this on other trucks in the past

 

I thought i was having a starter issue as well till i bumped the shifter and it fired, will get to that someday too LOL

 

have you switched the starter relay with another relay to rule it out?

 

no, that is where I am looking next. I had to dig and find a diagram as I was not familiar until recently about it.

 

I had the same issue with a brand new starter from Advanced Auto after only a few months.

Turns out that it was a bad starter. Replaced the "brand new starter" and all good.

The bad starter still started the truck but not very well.

2001 PSD Ex

 

that is why I bought a new one vice a reman starter, been there done that