I need help, I have a 1990 E350 with a 7.3 diesel. Recently the starter quit (was cranking fine then after about 10 seconds started realy straining to turn engine) I pulled the starter and dismantled it. The brushes from the fields were quite worn and one was completly unwired. I got a new set of brushes (all 4) and wired them in and put the starter back in. When I turned the key it just went click and the starter made a grinding type sound. I pulled the starter again (it was quite hot to the touch) and decided on a replacement. I put the replacement in and still nothing. I checked all the wires and found one bad connection at the solinoid and replaced it. This truck has had start problems since I got it, the previous owner did lots of rewiring (not very well though). Could the relay be shot and does anyone know for sure which wire goes where on the relay as these had all been replaced by him as was evident by the amount of electrical tape and twisted wires.
Thanks for any help as I need the truck for business in a couple days or else I will have to rent a cube van for my haul.

 

on the starter soleniod there are 4 connections. Im not sure about this but if you hook some wires up to your battery you can try it. There are two big studs. I believe the left one is for power (connected to battery) the right big stud connects to the starter. THere are also two smaller studs on which i believe the right one connects to the ignition and triggers the solenoid to start the starter and the left one is a booster that goes to the ignition module. If you take two wires, from the battery, put one on the left big stud and one on the right smaller stud you will hear a click and that means you have them correct. If not try other combinations. hope this helps

 

On a gasoline engine the small terminal closest to the battery terminal is the start terminal. I usually take a screwdrive and touch the small term to the battery one to crank the engine. You can test the solinoid by measuring the voltage at the terminal to the starter. Try cranking the engine. The voltage should close to the battery voltage while cranking. There will be a slight drop normally.

 

Those terminals are marked S & I.

The I terminal for the Ignition circuit getting 12v at start up.

The S terminal is the one that triggers the solenoid for power to the starter

Dennis

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There are only three terminals on this relay (solinoid). There are two large ones and a small one. I know which wire runs to the small one as it is smaller and only will fit there. I imagine that the battery hooks to one of the large ones and the wires for starter and glowplugs circuit go to the other large terminal. I just don't know if it makes a difference as to which large one I use and if I will fry the relay if I don't get it right.
Thanks

 

Since you only have one small terminal "S", the battery can go to either of the large ones. I don't think your glowplugs would go to the starter connection. They would only glow while cranking. :-X12

 

The large terminals can be connected to either wire, and you won't hurt the relay. All it does is connect the 2 big terminals when there's 12V to the small one and ground to its steel base.