Hello everybody, just traded for a 97 4x4 ext cab dually. got it real cheap. It has 113k on it. It was hit in the front and the trans(5sp) was rebuilt but still out of the truck. It has been sitting for over 2 years. The dash was completely dismanteled so mice would not get in there. My first problem is the sterter, After I put the dash back together and the front end I tried to crank it and just got the`` click``. When I pulled the starter off, I found the contacts were wore, so I fixed them and figured it would start. Still click ,click,click. The solenoid is not pulling the plunger in far enough far the contacts to work. We even tried the starter direct out of the truck with jumper cables. What can I do to fix it? Can you replace the solenoid? I really would like to here this engine run before I spend a bunch of money on the truck. Thanks , John Mark Zavadil. P.S. i hope to be selling my powerstroke soon The plunger was stuck to the cover. I kept thinking it was someting simple . The engine started it 10 seconds. Thanks for helping

 

My first thought is that if the truck has been sitting for over two years that it is possible that there is corrosion between the brushes and the commutator. Yes, the solenoid contacts may have been worn but after that time there may be other problems. When the starter was out did you try turning the armature with a screwdriver? Just a turn or two may be enought to make the brushes contact properly.
Have you checked the wires from the battery terminals (both of them) for proper electical contacts. ie is there a good ground to the engine block? You did say you tried the starter out of the truck with jumpers so that does tend to look like the starter itself, but also check the rest of the stuff. How about the batteries? Are they fully charged?
If the starter is still out of the truck take a meter and check for continuity between the wire that comes out of the starter and goes to the solenoid. Check between that wire and the starter case. That should show close to a dead short. If it shows an open circuit then it is probably the brushes. Also check with an amp meter or a light on the output of the solenoid when trying to turn the starter over. When the solenoid clicks there should be at least 10 volts, more if the starter is not turning over. No juice, then it is the solenoid.
Hope this helps.

 

The starter motor spins good if you jump the lead wire going to the motor. Is the brass ring on the plunger supposed to be loose? I don`t understand how it can make good contact if there is not any pressure behind it to hold it against the two lugs.