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I had a no start on my '96 F350 PSD ( the relay would click ) , batteries checked out as did the starter and connections . The truck sat over night and fired right up , then did the no start thing again after driving 10 mi. I had it checked out at a local garage and they also said everything cecked out fine ! But said in their expirence it was most likely the starter . I had them replace the starter as they had one in stock and I was already there , anyway ..... The truck started fine on our way home from Michigan to Florida and has started every time since . Any thoughts as to why the starter would not work and then work by just setting ?
the starter solenoid has contacts inside that "make up" when it is energized and the plunger pulls back and pushes the drive into the flywheel. as the contacts burn from the constant arcing, they get bad spots in them, which will creat a no start/start problem. it also could be the brushes inside the starter which have travel limiters and sometimes when they reach that point, the little bit of "jarring" for the solenoid action will allow the brushes to make contact and it will start.
Yeah , that was my first thought too fedex . But it kinda confused me when after doing nothing but setting over night it started ! I have "tapped " a bad starter/selenoid before , but I didn't do it this time .
one other thing...the greedy factor! the shop might have noticed a bad connection at the starter, BUT decided to put the starter on anyway and at the same time, the loose connection was eliminated. it happens too often ! i hope you got a stater with a lifetime warranty ! have a good day!