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I have a 1999 Ford F250 7.3 and I am looking for some help. When cranking over the motor sometimes a relay behind the ashtray clicks rapidly. When this happens the motor with not start. I then have to turn the ignition off then on rapidly untill the relay does not click which will then allow the motor to fire up. I have replaced the relay and found that it was obviously not the problem. I have determined that the batteries are not the problem. I am guessing i may have an ignition switch problem, but before just buying a new one I am looking for some input on how to test the current one, or see if anyone has had this problem. Can anyone help?
Sounds like a loose connection on a contact. The relay is not getting its full voltage causing it to chatter. Are you getting any trouble codes popping up? Check all your connections on your ignition relay.
Welcome to FTE. 99% of the time, that clicking relay is caused by weak batteries or poor connections. Did you have your batteries load tested? Remember the glow plug system puts a pretty good draw on the batteries when you turn the key on.
Check your connections and make sure they are clean and tight. Don't forget the cables have other ends on them. Check where they ground and hook to the starter relay, etc. too.
Also this is my third set of batteries. Thank god for Sams Club return policy. The wierd thing is that if I hear the relay clicking I turn the ignition off then back to start as fast as my wrist will turn it. I do this repeatedly until the clicking is not there. Then it will start. This has worked everytime. If I had bad connections would this happen?