Intermediate starting problem

[KennyB]

Hey guys, here’s my problem. Once in a while I’ll turn the key and just get a click. My gauges still operate and seem fine. sometimes I try again and it works fine other times it take several tries. when it turns over it starts right up.

I have a 2000 K3500 6.5 diesel. New starter/solenoid, batteries test fine, alternator test fine, new starter relay, the ignition switch was replaced a few years back. new Heath pmd relocated, new IP about 2 years ago, new computer about 3 years ago. I’m going to check the grounds tomorrow, battery terminals are good and clean.

I go on vacation Thursday which means I’m pulling my fifth wheel and really don’t want my truck to fail.

any ideas would be greatly appreciated.

 

[JMJNet]

How did you test all those parts?

New part do not mean they are good?
Is that ACDelco ignition switch?

 

[Will L.]

If you here the solenoid click- that eliminated ignition switch.
Possible problems:
starter solenoid
Starter motor
battery cable(s)
Bad connection of cables at battery, where they tie together (the spacer is common point of failure), bad connection to the starter post, bad connection ground cable, starter housing bad connection for the ground.

Probably not the issue, hut anytime starter is mentioned- must say: make sure you have the front brace on the starter to the block. That destroys tons of these engines when people don’t reinstall them.

 

[WarWagon]

I bet it does it like this. This was the start of a plague of bad starter solenoids on reman or new starters. A local auto alt/starter rebuild shop gave me two bad ones in a row. I recommend a Powermaster 9052 starter like for some better RPM, but, it's one of the few quality parts out there now.

11V at the battery cable to the starter minimum. 9V minimum at the starter solenoid.

 

[JMJNet]

Another thing, did the starter rear bracket installed when replacing starter?
That bracket is hooked up using the stud in the starter then a nut to mount it to the bracket.
If it is not there, it will break a chunk of the engine.

Was the starter bolt replaced with proper GM starter bolt of ARP starter bolt.
If not, it is probably not very tight.

So, it is not just the electrical but the installation of starter becomes very important.
It is a heavy chunk of metal.

 

[KennyB]

Thanks guys, I’m going to check cables today. the Old starter worked great until it didn’t lol The video is pretty much what it is doing. just nervous about traveling five hours for vacation, I don’t what to get stranded. if I can’t find anything cable wise I guess I’ll be replacing my starter with another one. Appreciate all the help!

 

[JMJNet]

Find a local rebuilder, they probably can rebuild it better.
Otherwise, if they have them in stock, they probably have better quality than the part store.

If you go to Part Store, you need to get a "NEW" not rebuild.

 

[WarWagon]

Find a local rebuilder, they probably can rebuild it better.

Make sure they are not putting a China solenoid on it. Or it's the same problem. New/reman/local rebuild shop all are reaching for the China Krap solenoid.

Again get a known good part, Powermaster, mail order and pay to have it shipped fast. Another same brand starter will have the same problem as it's made from the same krap parts.

What store you get this bad one from anyway?

 

[MrMarty51]

Notice in the video, one solid sounding KLUNK, that is the sound of a bad starter.
A series of click click click for as long as the key is held to start position is the sound of low battery voltage. Can be caused from bad battery or from a bad connection between the batteries and the starter.
If it makes the low voltage click click click noise, then disconnect every battery terminal, from batteries and starter and peel back that side post insulators from positive and neg cables, soak them in soda water solution, rinse with fresh water, blow dry and scrape, sand and wire brush them to bright and shiny. On both ends of all the cables.

 

[KennyB]

Update, I found some pretty nasty grounds. Also the main wire from the battery had been spliced and was loose. So fixed splice and cleaned the grounds. Did some errands around town. Seven or eight starts no problems so far. It was a brand new starter (not a rebuild). I realize now that the old starter was probably fine, because it did the same thing which is why I put a new one on in the first place. I really appreciate all the experience and help from you guys.

 

[MrMarty51]

Well, welcome to thetruckstop KennyB and keep coming back.
It is always nice to hear stories of success thats been guided through the forum.