I've checked and cleaned all the grounds I can find. Batteries are good. Starter is almost new. When i bench test it it works fine. When i turn the key to start it just clicks. 1 in 20 or so attempts to start and it will turn over. When it does turn over it melted the negative off the second battery. Re checked grounds cable batteries. Replaced neg clamp and now its starting to melt positive clamp? Any ideas would be welcome

 

got a short somewhere

 

I figure that any suggestions as to where. I just know its somthing stupid. I just can't find it right now.

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Anyone think it might have anything to do with neutral start switch?

 

couple things to check aside from grounds and neutral safety. First check o see if you have fuel at the test **** to the right of your injection pump. If you do make sure your system isn't air bound. If that doesn't work, then it could be the PMD on the side of the injection pump. It could even be the injection pump but that can be eliminated by cranking the motor with a injector nut loosened to see if you have fuel at the injector. Sorry but these 6.5's are a pain to diagnose, I had to find out all these the hard way. Good luck

 

Thanks for the in put. Will check out the injector pump. Only thing that sucks is vans are hard to work on. But have the passanger seat ripped out already. Cant get at the pump from rear, so i guess air intake has got to go. I'll let you know if it works, thanks.

 

I would all most say your starter is bad just because you bench tested it doesn't mean it bad cause you can't get the load on it like the engine does and if you are melting the cable ends there got be something wrong with that starter

 

I've got her all tore apart now. So I will check the injector pump. But i will dig up the reciept for the starter(still under warranty). Will probably be the weekend before i can get at it again. Thanks for all the input.

 

With those melted wires it shows you are pulling a lot of amps I will second that bad starter vote.