I'm having problems starting my 96 F350 PSD. I seems to be an intermittant problem. Some days I can start it normally, drive it all day it is fine. Other days, it will not turn over at all. Go to "wait to start" you see the volt guage power level decrease as if the glow plugs are getting power. Once you try to start the engine, you hear a single click. The motor will not turn over. When it has this problem, the only way I am able to start the truck is to place a screwdriver over the fender relay. Ive replaced the batteries, there new. The alternator was rebuilt a year ago. It is putting out 14.57 VDC. Batteries have been load tested as good. All connections to and from the batteries are clean. The fender starter relay was replaced as well. Any other suggestions Thanks

 

i think you just answered your own question. if you jump the relay and it cranks then your new relay is bad. warrent it out for another and try it

 

What would cause the starter relay to go bad after a week.

 

anything from corrosion in your battery cables to a poorly manufactured part- it happens

 

Ill replace the relay again and let you know. Thanks

 

if you have a multimeter, get your battery cable resistance readings and do a voltage drop test on the starter

 

Replaced the fender starter relay. Hmm Upon start up i hear clicks and i am not able to jump it at the starter relay I am thinking it is the alternator, because the batteries were dead. When it was running, I got 14 + VDC at the battery.

 

your going to hear clicks to reset relays I think if the key is on. If your batts were dead then you have a open short. I agree though that if you were to jump the relay and it started that it is obviously a bad relay. make sure that you have it wired corretly, and that you have connections secured so your not getting a voltage drop. Your on track, dont lose sight of the problem. If the truck is running and you got 14 volts, it could not possibly be the alt, batts dont charge themselves. If it was the alt, when you started it you would notice voltage drop, not when you had it shut off.

 

It is now three relays in two weeks. I strongly feel that I am looking at multiple problems. Just not knowing what they all are is frustrating. I think my next step will be hunting down the possibility of an electrical short.

 

Ok, disconnected both positve terminals of the batteries. Place my meter across post to terminal and read 12.39 VDC. Pulled every fuse in the truck, no change in the voltage. Any other ideas.

 

If you were searching for a drain on the batteries you should have set the meter to amps not volts. Be sure everything is off and all doors closed. If you have a hood light disconnect it. A draw of 50 mA (.05 amps) is normal, anything higher is a draw that may kill your batteries.

NOTE: There is a possibility of blowing a fuse in the meter if you have a draw higher than the meter is rated. Use a test light first...it should be very, very dim. If it's bright use the test light instead of your meter.

 

did you check to see if the glow plug relay was stuck on? and the alternator has occcasionaly caused battery draw on the trucks.

 

Checked for battery drain was a constant .01 dcmA. Is this amperage reading normal. Or is this reaing too low. Next check i the glow plug relay.

 

Checked GPR, Batteries disconnected all night. Re-installed batteries, 13.02 vdc at battery. At the GPR constant power scource was aslo 13.02 vdc. Attempted to start the truck and it started just fine. Quick to start and no smoke. I let it run for about five minutes, the battery voltage came uo to 14.35 vdc. I shut the truck off and restarted it. Hmm, it will not turn over. I am hearing a click as i try to start the truck. this is the fender starter relay and the starter. The starter feels as if it is enguaging, but will not turn over.

 

sounds like a starter going south maybe a high resistance in one of the windings or an almost dead spot on the commentator.