I have a 1992 Ford F-150 4.9 6cyl 5spd regular cab. Went out to start it and all I hear is a strong single clunk when I turn the key. I am not sure if the sound is from the solenoid on the starter or the relay on the fender well. The starter is a reman from advance auto parts and is about a year and a half old and was working fine until this. I tried jumping the truck but no difference. Is there a way to test the starter in the truck before I take it out. Thanks for any help.

 

Starters take alot of amps and will lower the voltage reading at the battery. So have someone try to start the vehicle while you hold the meter leads to the battery. I don't know how much it should change with power going all the way to the starter, but I would guess more than half a volt. You could also expect your headlights to dim when the starter is engaged.
You could also jump directly from the battery positive post to the small diameter wire connected to the starter solenoid mounted on the starter. Be sure to connect at the solenoid first. Probing around with a live positive wire could be dangerous.
Insure that the large diameter wire connecting to the starter solenoid is clean and tight. The battery connection should also be clean and tight. Be aware that corrosion can hide inside the connection and not be visible until the connection is taken apart. I have had an engine not start because of this problem.
You can also remove the starter and have it tested at the parts house for no charge.

 

Maniac, Do you mean connect the positive terminal of the battery directly to where the small spade terminal attaches to the solenoid on the starter? If this is correct what exactly should happen? Will the starter just spin or will it actually engage and turn the engine over if the starter is good? Thanks

 

You can just use a screwdriver to jump the selonid. If its clicking its usually not enough power to it. How is the battery and charging system?

 

Thank you all for your replies on this but it is still unclear to me what I jump to what to test the starter in the truck. Do I just touch a screwdriver to the small spade terminal on the solenoid on the stsrter to the large red positive connection which is also on the solenoid on the starter? Still confused Thanks

 

Do it as Maniac said above.

"Do you mean connect the positive terminal of the battery directly to where the small spade terminal attaches to the solenoid on the starter?"
YES

"If this is correct what exactly should happen? Will the starter just spin or will it actually engage and turn the engine over if the starter is good?"
It should engage and turn the engine, you will be bypassing the starter relay on the fender but not the solenoid. Make sure the truck is not in gear and the wheels are blocked.

 

I jumped a positive test wire from the battery to the small spade terminal on the starter solenoid while the starter was still in the truck and it did the same thing as before - Just a solid single clunk as the solenoid activated but no turning of the engine occured. I went ahead and took the starter out and bench tested it and got it to spin using the battery in my other car. Then to rule out the battery in the truck I bench tested it with the battery that is in the truck and it spun. Then I took the starter to advance auto parts and they tested it as good. I put the starter back in the truck and nothing but the single solenoid clunk as before. What should I try next? Thanks

 

Check your battery cables, and starter wires.

 

this may be a stupid question but how much oil is on the dipstick? What is the resistance of the wire feeding to starter and do you have a good case ground

 

The oil is fine and I can push start the truck and it runs fine. I just can't get the starter to spin. When you say wire to starter which wire do you mean - mine has three wires connecting to the starter - one is a ground and connects to the bottom starter mounting bolt.

 

Red thick 4 gauge wire. How many ohms do you have on it?

 

Sounds like the SAME problem I had. Starter relay and solenoid working just fine, just no current to the starter motor. Turned out to be the cable was failed INSIDE the clamp on the battery. There should be two large cables leaving the clamp on the + post. One goes to the starter relay on the fender, the other goes to the solenoid. Cut the clamp off, go to Wally World, and get a bolt-on replacement for $2.00. Mine showed NO signs of heat or anything. Clean connection, yada yada yada.

It IS possible the contacts have burned out in the solenoid, but that's rare as hen's teeth. Since your battery cable is probably OE, I suspect it failed just like mine did. Still running on the Wally World clamp two years later.

 

First of all thanks to everyone who responded on this issue. The problem is fixed. A special thanks to Subford and Old Paint. When checking the small spade terminal at the starter solenoid I noticed the insulation was very brittle and cracked so I cut it back and installed a fresh segment of wire with a new spade terminal(Thanks Subford). The next thing I did was install a new battery terminal to the negative battery wire. Truck still would not start. I then cut the two red wires from the factory positive clamp and installed a new terminal. Truck started very happily. The clamp appeared to be ok but was the problem all along. (Thanks Old Paint). I guess the moral of this story is check and double check all wiring before any heavy mechanical work. Thanks again to all!