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post #1 of 5 (permalink) Old 03-19-2015, 11:04 PM Thread Starter
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Starter Problem

I have a 2003 6.0l F-250. After sitting for 4 hours tried to start the truck and it wouldn't start, just clicks. I've load tested the batteries ( load tested good ), checked power at large terminal of the starter (12.3v), checked power at small terminal (11.9), removed starter and bench tested it ( worked fine ), replaced starter ( same problem present ), ran a jumper from battery to small terminal on starter ( solenoid engages but starter motor doesn't spin, checked starter relay to see if it's clicking ( it's clicking ), swapped starter relay for a known good one, performed pin point test per Ford manual ( all test good ), so I was afraid engine was seized so tried to turn motor by hand at the crankshaft dampener and it turned easily enough. I'm stumped. Any suggestions ?
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post #2 of 5 (permalink) Old 03-20-2015, 01:20 AM Thread Starter
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Re: Starter Problem

Forgot to mention the pinpoint test I used was pinpoint test B in the OEM manual for my specific concern - no crank relay does click. I also replaced batteries for S&G's also grounded frame and motor with two pairs of jumper cables one on each battery negative post. I'm going to pull the starter tomorrow and try to rotate the flex plate to rule out possible busted crankhaft but I really don't think it's busted because it ran just fine before shutdown. I'm scratching my head on this one. ?????

Last edited by Weser; 03-20-2015 at 01:26 AM. Reason: Misspelling
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post #3 of 5 (permalink) Old 03-20-2015, 01:34 AM
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Re: Starter Problem

I noticed you checked everything that pertains to the positive side but there's no mention of the ground side of the system being checked, which is just as important. Reread second post, my bad.

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post #4 of 5 (permalink) Old 03-20-2015, 07:38 PM Thread Starter
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Re: Starter Problem

So here is what I did this morning; pulled the starter and bench tested (worked just fine), turned the motor by hand while assistant watched through starter hole at rear of engine and everything was turning smooth. So, I decided to bypass all the wiring down to the starter. I attached the battery cable and signal wire and let the starter dangle under the truck. I grabbed a pair of jumper cables and went straight down to the starter positive to big stud ground to starter case. Hooked up my remote start to positive on battery and down to small stud. Pressed the button and she kicks out and spins !!! So, started taking a close look at the battery cables. I was going to do another resistance test this time isolating the cable from the terminal (original terminals we're replaced with the quick change type wears ago). I pulled off the first wire the one with fusible links to get at the one to the starter and when I went to loosen the second nut I noticed I was just a bit loose. Tightened it up and all is good. Goes to show you have to pay attention to every small detail with the electrical on these trucks.
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post #5 of 5 (permalink) Old 03-21-2015, 03:58 AM
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Re: Starter Problem

I may be off, but those voltages look low to me. A 12V battery should be over 13 fully charged.
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