6.0L 2005 intermittent no crank!?

[IXVolt]

My F350's been in the shop quite a bit and I keep hoping it will be reliable sometime SOON.

When the truck runs, it runs great. Starting it has always been the problem.

I've been having an intermittent problem with starting over the last year. Glow plugs light up, fuel pump engages, all gauges come up, then I turn the key to crank and nothing. No crank, no starter click, nothing. All the gauges and stereo goes blank like usual when you crank and start the engine. But nothing happens.

Sometimes if I leave the key in the cranking position it will crank and start about 2 seconds later.

No CEL's or other codes.

Truck has 108K miles.

Here's what I've done so far.
New FICM
New HPOP valve
New Cam position sensor
New injector HPO seals
New fuel pressure regulator spring.
New HPO rail plugs

Truck has 2 matched Interstate batteries that have been tested by Interstate recently and they are in great shape.

When it cranks it always starts now, so I'm pretty sure it's not the starter?

I'm thinking possibly the ignition switch maybe?

Other than that I'm really at a loss, and seeing how it's an intermittent problem, it's difficult to trouble shoot.

Anyone have suggestions on where to look next or what to try?

[dannyboy950]

Switch or a weak start relay are all possibilities as well as corrosion in the cables to the starter. Weak solenoid on the firewall or on the stater it'self.

[IXVolt]

Thanks, I'll start looking around at those.

[onebadpowerstroke]

Check your ground wires also they can cause some crazy stuff you will have multiple ones from the body to the cab and engine to body. Also make sure its clean where your starter cable connects to frame. I would also check the relay as mentioned above they are cheap and you can probley get one at a junk yard. Could also be a swith problem as mentioned above just so many things between you turning the key and the starter. You could always try jumping straigt from a battery to the starter with some jumper cables and if you get the delay you know its in the starter. It could be a dead spot on the starter.

[stp4132]

Any news? I've got the exact same issue so I'm very interested if you've found the problem.

[jrholod]

I, too, am wondering if you have any news. What was it?

[M90Ranger]

Try Unplugging the fan clutch when it acts up