94 IDI Will not crank
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4wd Low
Joined: Jan 2024
Posts: 10
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94 IDI Will not crank
Been making some repairs on my 94 IDI 7.3 Turbo and now it will not crank.
The following has been replaced:
Glow Plug relay
Glow plug wiring harness (Classic Diesel)
New glow plugs (8) Motorcraft ZD9
New injectors (8)
fuel return lines and o rings
New starter
New Starter relay
Tach sensor
New batteries
New battery cables
Any ideas? Glow plug light comes on as it should but starter will not crank. I will go back and check cables/grounds but this first started with a glow plug issue and I figured it would start right back up after these part replacements.
The following has been replaced:
Glow Plug relay
Glow plug wiring harness (Classic Diesel)
New glow plugs (8) Motorcraft ZD9
New injectors (8)
fuel return lines and o rings
New starter
New Starter relay
Tach sensor
New batteries
New battery cables
Any ideas? Glow plug light comes on as it should but starter will not crank. I will go back and check cables/grounds but this first started with a glow plug issue and I figured it would start right back up after these part replacements.
Last edited by Farmer Brad; Jan 3, 2024 at 06:21 PM.
Logistics Pro
Joined: Nov 2013
Posts: 3,930
Likes: 1,201
From: Mojave, Ca
The starter is independent of everything your replaced except the starter relay. Is the relay clicking when you turn the key to "start"? If not, then the relay is bad, is wired wrong, or isn't getting the signal from the key.
If it is clicking, then the problem is your starter. You may have a bad connection, bad solenoid, or a bad ground. What happens when you short a wrench across the big terminals on the starter relay? (Don't stand in front of your truck when you try this.) You should hear the solenoid on the starter clicking if the starter is bad, or the starter start spinning if it's good.
If it is clicking, then the problem is your starter. You may have a bad connection, bad solenoid, or a bad ground. What happens when you short a wrench across the big terminals on the starter relay? (Don't stand in front of your truck when you try this.) You should hear the solenoid on the starter clicking if the starter is bad, or the starter start spinning if it's good.
i ain't rite
Joined: Mar 2005
Posts: 65,625
Likes: 5,636
From: Marlboro Mental Hospital.
new starter relay does not mean good starter relay.
with the influx of cheap chinesium parts the past few years, sometimes i need to put 5-6 brand new out of the box starter relays in before i find one that works.
with the influx of cheap chinesium parts the past few years, sometimes i need to put 5-6 brand new out of the box starter relays in before i find one that works.
Thread Starter
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4wd Low
Joined: Jan 2024
Posts: 10
Likes: 0
The starter is independent of everything your replaced except the starter relay. Is the relay clicking when you turn the key to "start"? If not, then the relay is bad, is wired wrong, or isn't getting the signal from the key.
If it is clicking, then the problem is your starter. You may have a bad connection, bad solenoid, or a bad ground. What happens when you short a wrench across the big terminals on the starter relay? (Don't stand in front of your truck when you try this.) You should hear the solenoid on the starter clicking if the starter is bad, or the starter start spinning if it's good.
If it is clicking, then the problem is your starter. You may have a bad connection, bad solenoid, or a bad ground. What happens when you short a wrench across the big terminals on the starter relay? (Don't stand in front of your truck when you try this.) You should hear the solenoid on the starter clicking if the starter is bad, or the starter start spinning if it's good.
Logistics Pro
Joined: Nov 2013
Posts: 3,930
Likes: 1,201
From: Mojave, Ca
So starter is good. but the relay isn't sending power to the starter.
What happens if you tap a jumper wire from the battery positive terminal to the small threaded terminal on the top of the starter relay? (Again, don't stand in front of your truck when you do this)
If the starter spins, then the relay works and your ignition switch or neutral switch is the problem
If it does nothing, then you need to tighten the relay mounting screws, or the relay is bad.
What happens if you tap a jumper wire from the battery positive terminal to the small threaded terminal on the top of the starter relay? (Again, don't stand in front of your truck when you do this)
If the starter spins, then the relay works and your ignition switch or neutral switch is the problem
If it does nothing, then you need to tighten the relay mounting screws, or the relay is bad.
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4wd Low
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New ignition switch
New neutral safety switch
still will not crank
All wires and grounds look good
New neutral safety switch
still will not crank
All wires and grounds look good
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Thread Starter
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4wd Low
Joined: Jan 2024
Posts: 10
Likes: 0
thank you. Thats what I was thinking. Had this truck as my daily driver for 10 years and never had a filter with that. Going over wiring deeper tomorrow. Is there a fuse or something that might be out? Not sure what I'm missing.
i ain't rite
Joined: Mar 2005
Posts: 65,625
Likes: 5,636
From: Marlboro Mental Hospital.
what happens if you jump battery power to small terminal on relay? the starter should spin.. if it does not, either the relay is bad, or not grounded.
if it does spin, it is not getting power from ignition switch.
what trans, auto or manual?
if it does spin, it is not getting power from ignition switch.
what trans, auto or manual?
Thread Starter
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4wd Low
Joined: Jan 2024
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When I jump battery power the starter spins
Last edited by Farmer Brad; Jan 8, 2024 at 12:06 PM.
Thread Starter
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4wd Low
Joined: Jan 2024
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Tried a second neutral switch thinking it was a bad one.
Now the starter still will not crank and the dash lights flicker, "error" on the factory stock radio?, and the glow plug relay clicks rapidly and repeatedly. Checked all wires between the starter relay, neutral relay and ignition switch, all good. What could be causing this electrical problem?
Now the starter still will not crank and the dash lights flicker, "error" on the factory stock radio?, and the glow plug relay clicks rapidly and repeatedly. Checked all wires between the starter relay, neutral relay and ignition switch, all good. What could be causing this electrical problem?