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We just bought a 1996 F350 7.3 Powerstroke. Ran great and now won't start. We shut it off Friday night. Saturday morning it cranked and blew some smoke and acted like it wanted to start and then just started cranking. It was about 30 out so we plugged in the block heater and tried again about 2 hours later. It just cranked. Later we replaced the glow plug relay. No difference. Just cranks.
We cleaned the battery terminals. We have also checked the oil - good - and replaced the fuel filter. Nothing changes. The tach does move up some (maybe 100 or 200 rpm) and bounces around when the engine cranks. Since we just got the truck we don't really know it well to know what is normal. The prior owners said they could never get it to start if the block heater wasn't plugged in.
It sounds like it might be time to put glow plugs in the truck - sounds like the are shot or at least not working at all, and you said you replaced the relay. Blowing smoke when it's cranking means your getting fuel so the glow plugs would be my guess.
my 97 inthe shop for that same problem cranks good no smoke and tach jumps ,my IDM died (injector drive module),check if oil pressure needle moves and the high pressure oil pump is ok ,about a grand for a bill but hopefully you got a warranty???