Stumped with the Starter!!

[02Powerstroke4x4]

I'm utterly confused. I know that the problem is there, but I don't know how to locate it.

Let me start: I was headed to work one day, and noticed in the morning that it was starting a little weak, maybe took 4-5 seconds to start, abnormal to say the least. Anyway, the drive went fine (took about 45 minutes), nothing out of the ordinary except for the delayed start.

After work, I went to start my truck, and what do you know, it wouldn't start, turned over about 4-5 times, very weak. So, I thought it was the batteries, grabbed a forklift (massive generators for jumping) and a multi-meter, I first tested it - the batteries were fine. Then, I hooked up the forklift to jump it, and hopped in the car, and nothing...The relay clicked but that was it. I had my buddy turn my car over as I hit the starter with a wrench, it tried to start over, but wouldn't. And white smoke was coming out of the hole in the starter.

I took the starter off the truck, and bench tested it and it seemed fine, it engaged and spun fine, the teeth are fine, no debris or oil in it. Just fine. So then I hooked it up to the positive and the ignition switch and turned the key over without installing it, nothing happened.

So, I figured that the wires were bad, I switched out the wires, and replaced the ignition relay with the accessory relay and tried it again, but nothing. So I'm completely lost in my problem solving. I don't know if it is the CPS or the HPOP, maybe the Coil Plug Relay, I don't know. Any help would be greatly appreciated.. Thanks in Advance!

[zaidtoronto]

its funny, just happend to me . replaced starter, battaries, checked cables. turnd out to be starter selinoid mounted on the passenger side finder from inside. good luck

[jesilvas]

Yep, could be that solenoid. Also, that forklift was 12V right?