My husband's truck has always has starting issues, but its getting worse. I had a few questions for you guys... Is there any common wiring/ ground issues in these trucks? The batteries are good and both have a full charge, but the starter doesn't sound like it is getting the power it needs. I am assuming that one of the two grounds is loose, is there anything else I should be looking at?

Thanks!

 

toyotachia,
Welcome to FTE and the IDI diesel forum.

Several areas that might be where the problem is.

What year and engine are we working on?
There were a couple differences on the engines over the years, knowing which it is makes it easier to figure out.

Also any idea how many miles are on the engine?

As far as wiring, possibly the positive battery cable.
Does the passenger side positive cable look like it has been hot at the terminal clamp?
Brittle or discolored insulation on the cable where it goes into the clamp would indicate a bad wire connection inside the clamp.

How many cranking amps are the batteries?
850 CCA is the minimum, bigger is better.

Are the glow plugs working?
Burnt out glow plugs will make the engine hard to start.

Any fuel leaks on top of the engine?
If fuel is leaking out, air is leaking in and can also make for very hard engine starts.

 

Sorry I forgot to include the year, it is a 1993 w/ 180,000 miles. glow plugs, glow plug relay and starter where all replaced recently. It does seem like a charging/ electrical issue because the voltimeter reads real low on even the first crank. Jumping the truck also seems to help.

 

I am going to say either the battery cable is about gone or the starter has been overheated and is about gone.

Since the volt meter reads low, I would check out the cable first.

Use a multimeter and check the voltage with the probes on the battery terminals.
Now check the voltage at the starter relay mounted on the fender.

Given the sensitivity of the multimeter, you may have to check with the lights on or while cranking the engine.

If the readings are different there is probably corrosion in the ends of the battery cables inside the clamp.

And the clamp should get hot when you try to crank the engine.

All power on the truck goes through the passenger side positive battery cable clamp.
I had issues on my 86 several years ago.

One night it made me so mad, I cut the clamp open with a die grinder.
When I saw how much corrosion was inside the clamp, I don't see how it ever started.

It cost a chunk of change, but NAPA made me a new cable cheaper than Ford wanted.

2/0 cable from drivers side to passanger side battery, 3/0 from passenger side to starter and a piece of #4 from the passenger side battery to the starter relay.

 

i vote cables and connections.

 

Find out which glow plugs were used if they were NOT Beru motorcraft ZD9 then they may be the problem now...... most other than Beru GPs will burn up in short order. Can't PM you my email addy so I can send you the GP system electrical test and other info. You can PM me if you wish.......I think. You have less than 25 posts so things here are limited until then for you.

PS looks like your AVATAR of the Toyotachica she is sitting on a 56/7 Thunderbird.

 

I replaced the glow plugs, but I don't remember what I bought... It was from a parts store, not the dealer, so I bet it wasn't motorcraft GP. I personly, somehow, don't feel like it is the glow plugs. I think because It is warm temps right now and there is NO starting and the starter sounds slow, not just hard starting, until a jump or a stroke of luck (at random times, it starts up just fine). The starting issue happens warm or cold.

'56 thunderbird makes since, I bet that is about the time this pin-up was around...

 

Some parts stores have or had Motorcraft/Beru glow plugs.

If the glow plugs are working right, the engine should fire in less than one full revolution.

Clip the ground clip of an automotive test light on the positive battery terminal.

Now remove the wire connector from the glow plug and touch the testor tip to the terminal on the glow plug.

Lights up, the glow plug is probably good.
No light, the glow plug is bad.

Repeat for all 8 glow plugs.

Another indication, on a 93 the wait to start light should come on for about 10 seconds for the first start of the day.
If it don't, that is also an indication of dead glow plugs.