I did search and didn't find anything directly related to what my problem is. I have a 96' with a 4.9, 2WD, manual. I'm having an intermittent starter problem. I replaced the starter with a reman. 1 month later, the truck doesn't always start. I turn the key and hear the starter "clink" but nothing. The weird thing is, if I roll the truck about a foot as if to pop-start it, the starter usually engages and I'm running. Sometimes I have to actually bump it a bit as if to relieve pressure off the starter and it will turn over. The problem is, it is so sparatic I can't diagnose the solution. Does anyone know which wires I need to by-pass on the clutch switch so I can start eliminating the source of the problem. I don't think it is the solenoid (on fender). I just want save taking the starter off and having it tested, only to be told it is something else. All the electrical connections are clean and tight. Any help would be great. Thanks, Greg

 

I know i had an issue with mine that eventually got tracked to the signal wire to the solenoid on the starter. Clicking it would work sometimes because it would finally make a good enough connection to complete the circuit. Check your grounds, and even the cable from the + of the battery to the starter. The resistance between the 2 points should be no more than .5 ohms.

Also try the wiggle test. Pull the coil wire and have someone crank it while you wiggle the wiring. If you get a dead spot, and the motor stops cranking, then you know where your issue is.

If the truck is set up like my 92, then there are 2 solenoids. One on the starter and one on the fender. Just because the one on the fender is clicking, doesn't mean the one one the starter is.

 

I've seen people have complete nightmares with Reman Auto zone starters. But for one reason or another, it's always the Ford ones that are horrible. Everything elkse seems to work just fine. Just food for thought in case yours is of the Autozone descent

 

Thank for both of your responses. I have a feeling it is the starter because I know of issues with this rebuilder. I was hoping there might be a way to diagnose other issues before removing the starter again. I guess I should have just spent the extra 70 bucks for a brand new one.

 

had that problem,2nd wire(fusible link?)on the stater was almost completely broke in 2,spliced in new wire,no trouble since.

 

I ended up taking the starter back and got another one. It fixed the problem, now I have a connection problem. I think my battery cables are loose/dirty on the battery. It was working fine and now I have no juice and my gauges shut down when trying to start it. I think it is time to get a new truck. This one has served my faithfully for three years, but now it is nickel and diming me to death. I also saw yesterday while changing the starter that my rear spring shackle has rusted off and my leaf it pushing up on the bed and almost pushed through. ARGH!!