35xj

this forum has been a great help to me on my third gen, so i figured id give you second gen guys a look.

My dads truck, 02, 5spd, 2wd, 2 new batts' stripped truck. Wont start.

he lives a couple of hours away, so i,ve not had a chance to mess with it myself. But heres the symptoms...

It wont start! wont turn over, dead!

i had him browse the forum, and he came up with a couple things:

- jumping across the starter, it fires right up
-he read something about continuity across the ign switch, it was "bad" so he replaced the ign switch
-swapped the relays around under the hood (dont know if that is acceptable to diagnose the issue, but he was under the impression they are 4 the same, so swapping them should find the dud?)
still no start, apparently no codes

Any thoughts?

s-cube

when the starter contacts were just about worn out on mine, I could turn the key on off on a couple of times and it would finally start. search this section for threads about starter contacts.

KATOOM

Sounds like a starter/contacts issue. Sometimes there will be an audible click when trying to start the engine if the contacts are worn or sometimes there will be none. Sometimes the contacts can be worn in such a way that the solenoid plunger will ground and cause the starter 20a fuse (located in the underhood fuse/relay box) to blow which will result in nothing happening. If that fuse is blown then those contacts are in need of replacement. Very east job but does require getting under the truck to pull out the starter. The contacts are available for about $25 at various vendors or possibly a diesel performance shop close to you.

BigIron70

If truck has manual trans most likely clutch switch is bad or became unpluged somehow. It's under the knee bolster where the clutch rod goes out thru the firewall. You can jump across the switch and it will start but make sure you are in neutral or steping on clutch because it is a safety feature to prevent starting in gear.

SIXSLUG

Starter contacts. Replace with the bigger ones from the guy in Tacoma WA. YOu can get them mail order from Geno's Garage.

35xj

hmm. he has bypassed the cltch switch, if the starter contacts were the issue, would it still fire perfectly when jumping across the starter with a screw driver?

patdaly

Have him swap the starter relay in the PDC for another one and see if that fixes it. If not, check out the wiring under it for corrosion, also possible Ignition switch.

BigIron70

Clutch switch open would cause a no crank, check fuse #9 (inside cab left side dash pull the little cover if blown will also cause a no crank. Possible excessive current draw from starter solenoid then, shorted solenoid.

SIXSLUG

Good point, missed that little gem.

I am not sure you would have an energized solenoid though with out a working clutch pedal disconnect.

My next thought would be the ignition switch and related fuses and relays.