The truck is a 1992 F350 Dually with a 7.3 IDI.

I replaced the starter solenoid, mounted on the fender well. It would click periodically, and it actually was bad. One of the posts was loose in the unit. So ... Brand new on there.

The Starter cranked excessivly slow. I have two brand new Deka batteries that are 875 CCA each. The connections going from the Battery to the starter & solenoid are clean. The battereis are fine.

As I crank it, if I hit it with a hammer, it would speed up to almost normal cranking speeds, and then the truck would fire right up.

I decided to replace the starter, so I got a remanufactured one, new in box, with the papers saying it passed their standards test and everything.

Put the starter in, go to start it, and it fires right up. It cranked harder and faster than it ever did before.

I take the truck for a small ( 20 minute ) drive to get it hot. Bring it back to the house, shut it off ( Hot still ) and go to restart to see if having a good starter helped in Hot Starts ( Was hard to get started once it warmed up, but it cranked ungodly slow, the old starter was JUNK ) Turn the key, wait to start goes off, and I go to crank it. Nothing its just clicking. It makes a single click. I tried hitting it with a hammer a little to see if that helped but nothing.

I pulled the connections back off to make sure they didnt have grease/**** on them from the install, but their very clean. I noticed that the starter is getting hot too.

Anyone know what/where the grounds are that I can check ?

Im open to suggestions. I need to get this thing back on the road soon. Its killing me having to drive my Camaro everywhere.

 

most rebuilt starters and alternators from auto parts stores are garbage. they are done under contract by independent rebuilders, most of the time for a set price, and they only replace what is bad. you may well have gotten a starter that had noticeable bad brushes, and that was all they replaced. not the bad windings on the armature. so when it gets hot, the bad armature craps out.

 

if you stil have the original cables, check to see if the cable is bad internally. i had one that was junk inside the sheath and finally swelled up so much it was pretty obvious the problem was the cable.

 

See if the passenger side battery terminal is getting hot when you try to start it.
I was having start issues a couple of years ago and it about drove me crazy.
All battery voltage and alternator voltage goes through that terminal.
I cut it open one night and could not believe how much corrosion was inside the terminal, it looked great from the outside.

If the solenoid is just clicking, try wiggling the wire from the battery terminal that goes down to the starter.

 

Thanks guys ... I normally wouldnt have got a remanufactured, but this one was a Free-Bee so I kinda couldnt pass it up. The Cable is newer, not sure when it was replaced, but I checked it out, its fine. Im going to pull it out today ...

Thanks though for the help. I appriciate it.

 

Have you ever replaced the starter relay on the fender, it will cause the same problem.