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5.9 TD won't Crank..... Any ideas?

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So far I have tried the following:1) Charge and test the battery at NAPA -- battery tests out "Good"2) Test starter at NAPA -- spins easily, sounds good3) Removed starter solenoid cover -- oil on contacts, contacts and plunger are pitted. Cleaned and sanded contacts4) Clean and tighten battery terminals5) Clean main engine groundThe only idea I have left is to remove the positive cable and ohm it out to see if it has a broken connection.The starter contacts do not look like new, and are probably 8 years old. Is it possible the starter will run for NAPA but won't on the truck because of contacts?Thanks in advance for your help.

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  • Author

0V at solenoid terminal when in START position. Do you mind giving me some pointers on how this works? Is this likely an electrical problem with the ignition switch? I see a rod moving when I turn the key. All the accessories work when the switch is ON, and the accessories go off when the key is turned to START.Looking online at the part picture, I think I replaced this part several years ago :neutral:

  • Owner

Wiring diagram is a bit crude but it should help out...post-2-138698182238_thumb.pngSo check the starter relay and then check to see if there is 12V from the yellow lead from the ignition switch... It might also be a safety switch like clutch or auto trans safety...

  • Author

Thanks for the replies, very helpful.I found several pics of a starter relay, but haven't found one on the truck. Could I get a hint where this is located?On the right side of the wiring diagram is a rectangle marked "31". Is this a fuse or fusible link? Any idea where this is located?Thanks again.

  • Author

From the starter relay connector (starter relay removed), I have 12V when the key is in START on the yellow wire, from the ignition switch. I also have continuity from the starter relay connector to the starter solenoid terminal (brown wire). So the starter relay ($12) is suspect, and I will replace that next. It looks to be original. and I haven't replaced it in the last 10 years.

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