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Yesterday I started off to make my usual trip into town. The truck (97 F-150 4.2 5spd) turned over very sluggishly(slow) but managed to fire. About 7 miles down the road I decided I better stop for gas. Once again, it was slow rolling over and managed to start. When I arrived at my destination 13 miles later, I sat with the truck running for about 5 minutes,shut it off. Figured I better try and start it again(just for piece of mind I guess) and all I got was a THUNK! I never saw any indication of problems on my idiot gauges. I tried a boost to the battery and THUNK! I had a guy listen to where he thought the thunk sound was coming from and he said from the starter relay area. Could it be the starter or could there be another suspect??
Clean the battery posts. Clean the battery cable ends on both the (+) and (-) cables as well as what they are attached too (wire brush works well on what the (-) cable is grounded to). Check the battery cables for corrosion that leads under the insulating cover. If it looks green, get new cables, preferrably of larger than stock guage. Fully charge and have the battery load tested at one of the parts stores. It's free at most of them. Check battery volts with the vehicle off. Then start vehicle and check voltage. If your charging system is operating correctly you'll have a higher voltage read with the truck running. If no change, have the alternator/voltage regulator checked. Also the starter could be getting weak and that is magnified by heat.
Any one or combination of the above will affect starting your vehicle. Start with the cheap checks first. No sence throwing money at something that may be caused by a corroded cable.
Got a chance to look into the situation a little more. What I found was...the nine year old battery was still good (after getting it checked at the parts store) cables looked pretty healthy!(cleaned connections anyhow). The problem seemed to have been the starter! Took it off and had it tested. The amperage draw seemed fine, but the bearings sounded rattly. Replaced it and it has turned over and fired since. It even starts better(imagine that!). Thanks, Brian