My early 99 PSD starter sticks engaged. It was about -20 to -30 this morning. I cycled my glow plugs 5 times and turned it over, I turned the key to the off position and the starter was stuck engaged. I tried tapping the starter to disengage, but it would not. So I pulled the positive cables and it stopped. I tapped the starter while the cables were pulled and it disengaged. I tried again with a small truck jumping my batteries, same thing. Just a week or few weeks ago I installed 2 new Caterpillar batteries. Does anyone have any idea what is going on?

 

I cannot say for certain but when mine did this I had to replace the starter. I do not think you can get just the solenoid for the starters but that may fix it also. If it is any consolation, aside from the cost it was a very easy replacement. Maybe only took me about an hour.

 

There's a company that sells a 12 valve starter conversion that all you need is the nose cone I do believe off of your power stroke starter and it makes your engine crank over twice as fast and is ideal for cold starting conditions

 

more info please this sounds aw-sum !!!!!!!

 

There was a website I don't remember what it was called but they took the 12valve starter and put it in the ford starter nose cone and the gear reduction spins the powerstroke over way faster