Truck: 96 F250 7.3 powerstroke with a ZF-5. Got the truck in August so this is my first winter with it. Replaced the starter solenoid (Napa brand) in August because it went out.
Problem: When ever the temperature gets below, say about 25 degrees F, my starter will stick on (even with the key removed) until it kills the batteries or I can disconnect the leads of the batteries in time.
This hasn't been happening without my protest of trying to stop it, fix it and researching it. So far I had both batteries tested and they both check out to be good batteries and test to be good with load testing. The temperature got almost up to 30 degrees and I thought I would re-connect the batteries. Nope, because as soon as I did the starter kicked on. So I checked the starter solenoid by touching the leads to the battery without the passenger fender solenoid connected. Seemed to work by dis-engaging when I let go.
So I thought it was the solenoid on the the fender. Replaced it (from Napa) and it started and the starter dis-engaged. My flaw....The temperature was rising so I think it was above 30 degrees. Today, it was 16 degrees, so I thought I would test my handy work and yep the starter stuck again!!! Arggh!
Any advice would be helpful. I am tired of charging 2 batteries repetitively.