How many miles on it? I am stuck on it being the starter nearly everytime. If you're over 100k I would almost bet on the starter not turning it over quickly enough. They die so slowly you do not even notice them going south. With a bad starter jumpers or a boost charge will get it started for you, but before long not even that will work. Go back over all of my starting issue posts over they years and I've been right 9 out of 10 times.

 

That copper hat is a spacer between the IPR solenoid and the missing nut. You need to put a nut on there. As long as you can find one to fit it should be fine. But like I said, do not over tighten it. Try to find a slim jam nut. The nut and 0-rings are available on Ebay. You won't need the o-rings unless you rebuild the IPR but you will have the nut.

 

Thanks Markadeck, I agree completely with your assessment as I went through the starter issue a year ago but we replaced it then so I'm assuming (always a good thing) that's not the problem this time. Several previous posters suggested that I check the IPR nut and I've discovered that the nut is gone completely, I hoping someone can tell me if that could be the source of my problem and if I need s special nut or if its ok to just throw any generic nut on there. Any idea??? xtraveler

 

Chris,

You hit the nail on the head.

 

Most people have been able to find the nut laying on top of the motor. Take a flashlight and have a close look. Yes the IPR can cause a no start. I'm actually surprised you haven't had any problems with the truck stalling on you. If this isn't your problem, it ranks right up there with things that should be addressed ASAP.

Glad to see you're making progress on this.

 

Get a hold of this guy on ebay. He may be able to get you a nut. Click Here

 

Ok, good news and bad. I was under the hood instead of at the computer so I go the message to late but while going though hundreds of nuts in a coffee can I dropped a few on top of the motor and in picking them up found the original buried under a layer of grime in a place I didn't even know existed. I've put it back on and tightened up but since the solenoid rotates around I'm not sure if it needs to be aligned in a certain direction? Hopefully I have aligned wrong though because the problem remains. I had the batteries on a charger overnight so I tried cranking without the booster and after much longer than normal it did start but once again I turned if off and am unable to get it restarted. What difference did that little nut make anyhow?

I'm going to see about pulling both batteries out completely and get a ride to the parts store to have them both tested on a better machine (don't want to drive up there, turn it off and not be able to restart...) any other suggestions?

Thanks again,

xtraveler

 

No certian way except the plug and harness needs to be towards the top.

 

If you have the solonoid on the IPR with the wires facing the rear of the motor, & the nut is snug,, orientation is not important ...

 

True, but I can tell you it is much easier to hook and unhook that little wire retainer when it is on top or near the top.

 

Good point ...Many a time keeping it in sight as it tried to get away...

 

Well I can see a malfunctioning IPR causing problems with the HPOP reservoir, so that brings us back to Ricks suggestion.

Pull the inspection plug (torx fitting but allen wrench also works) and check your oil level in there. Oil should be within 3/4" - 1" from the top. If it's low top it off with your regular engine oil. Don't try and fill it all the way to the top. There's a stand pipe in there that will drain the excess down into your pan, but bring it up to 1/2" to 3/4" from the top, then replace and tighten the plug. If it was low, see how the truck starts with it topped off.

 

Is this issue solved? There's been nothing more on it so it's either fixed or given up on.

 

Well I have good news, I'm embarrassed to say that I've found the source of my problem. I quickly wrote off my batteries as the problem because they were both less than 18 months old (confirmed yesterday they were bought 06/07), they were the best batteries my parts store offered, they both registered fine on my charger, the battery gage in my ex showed above normal after a full charge, and my problems seemed isolated to starting. However, when I finally took them in to be properly tested we got strange errors on one of the batteries. We replaced it and the problem appears to be resolved. I guess thats what I get for assuming.

I can't thank everyone enough, without your help I would undoubtedly ended up at a crooked dealership (no disrespect, I know there are good ones out there but the odds are clearly not in my favor) who would have charged me money I don't have to fix problems that thankfully I didn't really have. Not to mention, I'm sure the missing IPR nut would have left me incapacitated once again. And I wouldn't have known about the the recall on the cps which now I'll have replaced before it causes a problem.

Its a remarkable testament to our age that so many knowledgeable mechanics can be united under a technological umbrella like this. And its a remarkable testament to humanity that so many people are willing to freely share their knowledge simply for the betterment of their fellow man. You are all incredible individuals and the world is a better place thanks to your contributions, so thank you once again.

xtraveler

 

I am really glad you got it solved. As I said in the Excursion forum, post it here. A LOT of really SMART people helping people.
From reading I've done here previously (and I'm certain someone will chime in and back me up, or correct me):
1. Good idea to replace BOTH batteries together.
2. Pick up an extra CPS and keep it in the glovebox.

Again, glad you solved it!!