The strange thing is that I can give it some throttle while cranking and the RPMs come up but as soon as I release the starter the engine dies. I had to do that several times until it finally stayed running.

 

Ok new stuff now.
I after cleaning the terminals I charged the batteries at 40 amps for about an hr switched it to 200 amps and hit the starter. the truck fired right up but was making an awful rattling sound as well as a whining sound I think maybe the starter was stuck. So I shut the key off and it keeps running. I was about to yank the fuel system relay when it finally shut down So I try it again with out the charger and I had to ride the starter again to get it to run but this time the whining and rattle is gone.

 

Read this thread and take heed
https://www.dieseltruckresource.com/...threadid=55233

 

Yep I found that right after I made my last post.
I can turn the key on and pull the solenoid in place and it starts everytime now.
The starter hasn't stuck since that one time but I have a new contact kit ordered.
Going to check for a bad battery as well.

 

according to the testing procedures here.
http://www.repairfaq.org/ELE/F_Car_B...CARBATTERY_006
My batteries are good.
I haven't cleaned the post on the starter though don't know if that could be it or not.
Something tells me that it is the contacts.

 

Replaced the contacts on my starter with the SUPERSIZE LarryBs today. The fuel solenoid seems to be good right now. One of my factory contacts was worn nearly paper thin.
I have a friend with a 98 Ford Powerstroke, he is wondering if his truck has a similar setup in his starter as well? Does anybody know?

 

Most all heavy duty starters have replaceable contacts. Whether the Ford's are the same type of contact I have no idea.

 

Contacts that engage the fuel solenoid?

 

Ron, Also keep in mind that when your batteries are not quite "up to snuff" the starter will pull more power then normal. That is usually when the contacts begin to stick. They heat up much quicker then begin to burn. Good batteries are a must with these trucks.
Tom

 

Yea I checked my batteries and they checked out ok.
On another note it's looking like I'm going to need to contact Goerend pretty soon.
I towed my buddies camper for the second time since installing the #10 plate and it didn't feel right on acceleration and now I seem to get a hesitation then a lurch when I take off from a light.