Yesterday morning I was headed out to work and the truck wouldn't start, just cranks. It cranks fast and I have plenty of battery. I drained the fuel filter (replaced 3k ago) and bled the bleed bolt. After cranking & cranking it finally started up and then died. Finally got it to start and it ran fine to work.

2 hours later I went out to fire it up during my break time and it started right up.

6 hours later when getting off work it took 2 cranks to get it to fire up. Ran fine and went to a gas station to get a drink. Came out and it wouldnt start. After about 5 minutes it started up and ran fine.

I went home, and about 2 hours later it started right up.

This morning it won't start again, and now I'm an hour late for work.

I drained the filter, bled the system, primed the lift pump....nothing. Outside temp is about 65 degrees.

When I pump the primer button I hear a squeak-ish sound somewhere behind the injection pump but I cannot see anything.

This truck has never had a problem like this in the past year.

'97 3500 CTD 5spd.

 

check the shutoff soleniod? also check overflow return valve.

 

How do I check these?

 

When you try cranking it over and its not starting, leave the key on. Pop the hood and reach under the shutdown solenoid to see if its lifted up all the way. Poor contacts on the starter, a freyed blue wire at the battery or a bad 70 amp relay will cause the solenoid not to engage at startup. Mine has been sticking lately and once I pop it up into run position, it fires right away. I have ordered a replacement relay as I have checked the rest out.

 

If that is not it, the overflow valve is located at the front of the pump on the engine side.It is the bolt that holds the line on.there is a spring loaded valve inside the bolt that may leak back and cause hard starting,but it is more likely the solenoid.

 

All signs point to a bad relay. I checked the fusible links and they were good with only the orange one having a bad connection, which I fixed. I had power at the relay, but not at the connection between the relay and the solenoid, so it looks to be the relay.

Just to make sure, yesterday, I manually pushed the solenoid up and she fired up but was hesitant to run and eventually died. I was thinking air leak or lift pump failure. After searching and searching I came up with no leaks.

Today I bled the low pressure side, then the high pressure side, manually pushed up the solenoid, she fired right up and I was out doing donuts and burnouts soon after.

Ordered a relay from Foster Truck a few minutes ago and impatiently await it's arrival. In the mean time I might rig up a pull cable.

Thanks for the tips fellas.

 

That "squeak-ish" sound you hear is the overflow valve. When it stops squeaking, it is time for a change.

 

Thx lil dog ! I had some battery issues seen the blue wire you were talking about .The blue wire had a bad connection truck started right up ! was getting no fuel past the fuel filter. : )