99 7.3 won't crank more suggestions please - Ford Powerstroke Diesel Forum
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Old 10-23-2011, 06:30 AM
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99 7.3 won't crank more suggestions please

Looking for help/suggestions.

Problem: 99 SD F250 7.3 running great before I replaced the fuel filter. Now will not start or crank over. Just a click like a dead battery. Had previous issues with clutch safety switch. Thought that was problem. Replaced switch. Still nothing. Traced clicking noise to starter relay switch under hood on passenger fender well. Jumped the switch with a screwdriver. Still nothing. When I jump the relay the clicking noise now sounds like it's coming from underneath the motor. I have not tested the batteries but feel confident they are not the problem. Both purchased recently from NAPA. Also the WTS light is functioning properly.

Any ideas you all might have will be greatly appreciated.
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Old 10-23-2011, 06:52 AM
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I had a similar problem with my truck, same noise, replaced the batteries and starter relay, and had the starter tested. What was happening was out of nowhere the starter began jumping from the + wire to the ground which would just cause a click. I realized this by laying under the truck as a buddy tried starting it, I could see the spark. After removing the starter and wiggling wires it would start up fine but as soon as I tried starting it again same problem. Luckily the starter was under warranty and that solved the issue. Good luck man!
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Old 10-23-2011, 08:04 AM
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Yea, I'd be thinking Starter too....

Try "rapping" on it with a hammer a few times to reseat the contacts in the Bendix. When jumping the solenoid on the fender you've pretty much eliminated everything but the wires, low batteries, and the starter itself.

Turn on your headlights and see if they don't dim significantly when you try to crank it over. If not, there's no load being applied which might further confirm the problem's Not with the batteries (leaving cables or starter as the most likely problem)
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Old 10-26-2011, 07:04 AM
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i had the same situation a few months ago i thought was the starter also so i stared to pull the starter and in process i found the positive cable to the big lug on the starter was rotted off and not creating connection i would check this out - was cheap fix - pulled the cable out and replaced the connection - its a 2/0 cable end - we had them at work (semi shop) also had the crimper

in the process i found the ground cable ends were all swelled up with green corrosion - so i cut green section out and put on new neg ends at the battery
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