I would be grateful for any knowledge, help, information, etc…

The truck will randomly click once (guessing starter solenoid) but will not turn over. Then try several more times and it will randomly start easily. Sometimes, it starts first time, and sometimes it doesn’t after numerous tries.

Here is what I have done so far:

- Put a new starter and solenoid in (bought as a single unit)

- Changed out starter cable.

- Changed out batter cables

- Change out battery terminals

- Changed out the fusible links that go to the starter (they look like molded pieces on the wire)

- Changed out the ignition switch (also played around with the adjustment with no luck)

- The batteries are Die-Hard, 650 CCA, and right at one year old.

On the batteries I gathered the following voltage data

1. With Engine off - 12.79 both
2. Got truck started measured 14.65 both (idle)
3. Voltage stayed the same when engine rpm was increased
4. After driving truck for about 10 minutes and idling - 14.76 both
5. Turned truck off and measured 13.65 both
6. Attempted to start truck and it clicked
7. Put voltmeter on battery and attempted to start, measured 12.7 in both while key in start (crank) position

I did see on some posts about the starter possibly not being ground properly. This problem started with the old starter in after driving for over a year (hence why my first move was to change out the starter)

Is there anything else I can try? I would be grateful for any knowledge as you might have guessed this is becoming frustrating.

 

The manual's troubleshooting flowchart suggests you may have a bad ground to the block. If you didn't change that cable, might want to check it.

 

Thanks for the response. I changed the cable, but let me go and double check the connection to the block.

 

650 CCA is not enough you sure you haven't burned up the starter?

 

The spec from the factory service manual is 2x 550 CCA batteries. In my experience, any two car batteries will work fine.