95 powerstroke starter NOT engaging

[motohead]

I have a 95 F350 powerstroke that will not start.I was cranking it today and after about 5 seconds it just stopped ( almost sounded like it seized up ).I had the batts tested and they are at 100%.Took off the NEW starter and had it tested at 2 different auto parts stores and they both said it was working perfect.I also tried jumping the starter solenoid and the starter just clicks.I cranked over the engine by had with a large breaking bar and it turned over fine.I noticed that the GPR is clicking and getting hot ,could that be preventing the starter from working ??.Also it is saying that there is water in the fuel could that be the problem ?? I'm a newby to powerstrokes and could REALLY use some help here.

Alan...

[mschn99]

ill bet your battery cables are loose or there is a poor connection. Clean and reinstall them and check it then.....

If this doesnt fix it, we will start looking at corrosion or poor wiring connections...

[motohead]

I have taken off the cables and cleaned and cleaned them several times.I checked were they go to the block ( neg side ) and the are greasy but fine ( I cleaned off the grease )Could the starter selenoid be bad ?? I jumped arcross the terimanels and it did the same thing.Is there anyway of going directly to the starter with power ???.

[mschn99]

if the starter is "clicking" the relay isnt bad....do you know how to check the resistance of a wire??

[motohead]

No I don't.The positive leads is getting worn out from being taken off so many times.Is it a ford only part ??.It is a cross over wire and it has 2 wires comming out and going to the rest of the truck.

[mschn99]

go to sears and buy a cheap DVOM (digital volt ohm meter, or multi meter)...will probably cost about 30 bucks.....when you have it i will go into further depth....

[motohead]

I just REALLY cleaned the batt terminals and cable ends with a cleaning tool and the sprayed it all down with batt cleaner and I also replaced all the cable clamp bolts so now I know that they are making the best possible connection.Can a batt cable go bad internaly ??.I'm afraid that something went haywire inside the motor..

[overl0rd]

Yes, it's possible the cable corroded from the inside. What clicks when you hit the key, the relay on the fender or the solenoid on the starter?

[motohead]

Both,I can jump the relay but I still get the same clicking on the starter.I just did a load test on the batts and both tested good but just barely.I had the starter test and it tested good ( it was only 6 mos old).