Ok fellows I need some definite help. I have a 91 7.3. When the batteries get weak (because its hard to start) The starter will not disengage. I have replaced both batteries, The starter solenoid on the inner fender and on the starter, the alternater I have tested the ignition switch and it seems to be functioning properly. I have also had the starter tested by three different places and they all said it if fine. As long as I plug it up it will start but if I don't and the batteries get weak before it starts the starter will not disengage even if I remove the keys. Its a 2 wire starter One hot cable directly from the starter and the other wire from the solenoid. I even crawled under the truck and removed the solenoid wire while it was turning over and it still would'nt stop. ANY HELP WOULD BE APPRECIATED!!!!!!!!

 

anytime batt voltage gets low, the solinoids can weld themselves together. the solinoid on the fender is bad. replace that again.


also what size batteries are you running? how are your glowplugs? age of injecotrs?

 

Batteries are new and 975 CCA each. I will try the solenoid. Glowplugs are Bad -----Injectors are original. If the solenoid was welded should'nt it stay engaged all the time? The only time the starter will stay engaged is after the batteries get weak. Thanks For the info!

 

when the batts get weak it will weld itself on.

if u say the injectors are bad, thats why it is so hard to start. how many miles on the injectors?

also have u tested the glowplugs?

 

Just replace all of your GP's. Truck will start cold within a few cranks. Also consider replacing the injectors.

 

Another night and Im at it again. The injectors are stock 170,000 miles Also How in the world do I test Gp In the truck or out of the truck? And now for another question. I just dropped 1900 in a new automatic trans rebuild and tonight I noticed a strange humming sound coming from the trans pan. I thought I had a battery drain problem and this might be it. Its definately electrical because it stops with the battery cables off? Thanks again fellows and hopefully I will get old Bestsy straightened out pretty quick.

 

ok, with 170000 on stock injectors, it is time for new ones. get a good set of injectors from oregon fuel injection or the like. stay away from pensecola and DPS.


as for the gp, remove the wiring from the plugs, take a test light and hook the clamp side to batt positive. now probe the plug where the wiring conected. if the light lights, plug is good.