Powerstroke having battery or starter issues possibly.

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Was struggling to start the last couple days and really struggled the last time I started and now after checking the battery’s and one was dead but the other still good so I just replaced one with a good used one that’s less then a year old and after installing them back in they wouldn’t start the engine. And I put a charger on it for a few hours at 6 amps and the battery’s had 12.7 volts in them before starting and I turned on the glow plugs and one battery went down to 11.7 and I tried starting it and not much power. Starts turning over slower and slower. Maybe the new used battery’s is not that good? The guy at interstate battery said the customer thought it was bad the guy working there said it’s good so I gave him 60$ for it. Said 795 cca and 1000 ca I think. Any ideas? Maybe just get a new battery?
Reply:BUY A BATTERY LOAD TESTER.  OTC has a nice one, Harbor Freight has a cheap one.https://www.harborfreight.com/100a-6...ter-61747.htmlhttps://www.nationaltoolwarehouse.co...All%20Products  This is the one I own, but the other one is probably good too.I dunno how you've been testing batteries, but a simple voltmeter test is not reliable.Another sign of a bad battery is the inability to take a charge.  If you look at your charger on low amp charge, and if it stays at 40amps without falling..........it's not taking a charge.  At best, you're getting a surface charge.And don't buy used batteries.  Unless they'll take it back, you just threw out $60 that coulda been used to buy a new battery.................which now adds $60 to the cost of the new battery you might actually needAlso......check the cable terminals.  If corroded, they're a good source of starting troubles.Starter draw is another place to look.  Check starter draw.......it can be significant if it's bad.
Reply:also, on a diesel 2 battery system, replace both batteries with same kind. it has always work for me on my 7.3 and 2 replacements on my duramax.  same thing on my 12v allis chalmers 816 backhoe with 2 batteries.lincoln 125spmonkey wards 250 ac/dcmiller 211 w/spool gunahp  200 sx tiglotos ltp5000dof course duramax diesel
Reply:If you have the voltage only dropping to 11.7v with the GP's On AND engaging the starter doesn't go much lower, then I don't see this as a battery issue (I'd check those plugs though, I don't think they're all running). On a charger, drawing only 6A (unless it's just a tiny charger), means that the batteries couldn't have been all that low either.More likely, this is a bad connection (cable end - either side / either polarity, or a bad, "high-resistance", cable itself) or even that the starter could be crappin'-out.Scrape, clean, grease, tighten everything, look for signs of corrosion (you'll often see green crud where the copper goes into the connector for a sign that the cable itself is in bad shape. They are, afterall, 20 yrs old now  ). If you don't see any of that, put a voltmeter at the starter and see what the voltage is there when you crank it over...Oh, and yea, NEVER replace only One battery, the one place you don't want to cheap-out on is the batteries. The plugs alone can draw close to 150A before you add the starters load, they're really important on our trucks!
Reply:Originally Posted by motolife313Was struggling to start the last couple days  The guy at interstate battery said the customer thought it was bad the guy working there said it’s good so I gave him 60$ for it. after installing them back in they wouldn’t start the engine.
Reply:Moto most auto parts places “the big chain stores anyway like advanced auto/O’Reilly’s/Auto zone etc etc etc” will load test your batteries for free as well as your charging circuit with vehicle running.  Can’t have loose and or corroded connections.  That is the quickest way to kill both an alternator and battery.Another tip,  periodically check the fluid levels in the batteries.  If they are lead acid bath batteries they needs to be maintained to proper fluid levels.  When you do oil changes is a good time to check levels imo.How is your intake tube looking after the cold air intake change?  How is your oil looking?Last edited by N2 Welding; 05-10-2021 at 02:59 PM.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:Originally Posted by N2 WeldingMoto most auto parts places “the big chain stores anyway like advanced auto/O’Reilly’s/Auto zone etc etc etc” will load test your batteries for free
Reply:Originally Posted by BaTuThe problem is though, all the parts stores have are dinky little 100A Load testers they use on cars and these are Big, Hi Amperage, diesel batteries that require 250-300A load to properly test. farmersammm is right, best bet is to get it on the right kind of tester, and I've used the HF 500A one for Many Years!
Reply:Ahh, if Only that's the way the world worked
Reply:When you were checking the voltage was that with both batteries connected? In order to get an accurate reading you need to test the batteries separately. Can you remove them from the truck charge both of them to a full charge and then take them somewhere and have them tested? As others have said it is normally a much better practice to change both batteries at the same time, they have both seen the same service and are probably in similar condition.Mike
Reply:I put 2 new batteries in and it acted like it had no power. I’m probably going to do a starter draw test next. The terminals are really clean. Check the starter connections and 1 small wire was a touch loose and I tightened it. He did take back the good used battery. He tested the battery’s again and said mine were good.
Reply:I’m starting to think it’s the starter. It has been turning over kinda slow for a while and real slow the last few few days. Maybe the 1 dead battery and only 1 starting it killed the starter
Reply:Check your cables at both ends before you yank the starter. They can also corrode between the lug and the wire itself... not just where they connect to the battery or the terminal. If both your batteries are 12 volts, running one down shouldn't have affected the starter as long is it was getting 12 volts. That's more of an issue where two 6 volt batteries are wired in series to get 12 volts... when one battery has a bad connection or gets weak, the starter isn't getting the full 12 volts and tends to fail prematurely. With a weak 12 volt battery you just lose cranking time. As other's have said, I change multiple battery setups all at once. Where there is room I like to switch them to the big suitcase batteries like they use in semi's... fewer connections to go bad and the price isn't much different than buying 2 or 3 smaller ones.250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLes
Reply:Originally Posted by motolife313I put 2 new batteries in and it acted like it had no power..
Reply:Did you rule out starter relay or solenoid?  Check for voltage at starter while attempting to crank engine?Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:Originally Posted by John TNot sure exactly what that means/no power. But in any case, another thing to check is the switch on the clutch pedal. On most of these trucks/it won’t start unless you push in the clutch. If that switch is bad/or going bad it will have you scratching your head. I cut the wires on mine and bypassed it.
Reply:Won’t crank at all If the clutch isn’t engaged and will test the starter tonight
Reply:Originally Posted by N2 WeldingDid you rule out starter relay or solenoid?  Check for voltage at starter while attempting to crank engine?
Reply:Would I just fix that part of the starter if so? I check it out. It’s a 01
Reply:You can run a jumper cable from the positive side of the battery down to the starter and jump it that way to see if the starter is good.  This way you don’t keep chasing your tail.  If the solenoid is on the starter it can be replaced.  If it is on the fender well it is easier to replace since the starter does not have to be removed.  It might be possible to change the starter relay on the starter while mounted to the truck but I have no idea what it looks like.  You’d have to make that call. If pulling the starter then definitely disconnect both batteries so you don’t go making sparks and shorting out the ECU or other volital electronics.Tip:  connect jumper lead to starter first to prevent arking and sparks then connect other end of the jumper cable to battery to see if it energizes.Last edited by N2 Welding; 05-11-2021 at 01:06 PM.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:Originally Posted by motolife313Would I just fix that part of the starter if so? I check it out. It’s a 01
Reply:It is usually pretty basic.  Main power leads go from positive side of battery directly to the starter solenoid then to the starter.  Negative is usually grounded in several places with the engine block being one of them.  Then you have smaller gauge positive wires going to the fuse box inside the engine compartment and inside of the cab.  One of those fused wires goes through the key switch for the temporary or momentary switch to engage the starter circuit thus energizing the starter.  You could have a blown fuse, bad relay, bad solenoid, bad connections, bad battery, bad clutch switch and finally a bad starter motor.  There may be something’s I left out but that is the gist of it.  Not rocket science.  The reason I asked if you checked for voltage at the starter is to rule our starter circuit problems or starter problems.  If the starter does not work start with the obvious problems out of the way being batteries and charging nnections to the batteries then systematically diagnose from there starting at the solenoid second to see if you are getting power when you energizethe circuit by turning the key.  You could use another person or bypass all the safeties and jump circuits if done correctly as to not back feed power in a circuit that is not related to the starter.Last edited by N2 Welding; 05-11-2021 at 01:08 PM.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:https://axleaddict.com/auto-repair/H...Starter-System
Reply:Originally Posted by BaTuOH! This is an Excellent Point!If you have a pre-'01 (and even some 01's), then you have a starter relay on the pass side fenderwell. Burnt contacts inside would do exactly what you describe. The easy test is to simply jump the two large terminals together (gonna spark some and will engage the starter motor) and if it cranks fast then you know your solenoid is bad...
Reply:Distributor has nothing to do with the starter.  Never heard that one before.  Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.I agreeMost time the solenoid needs to rebuilt. Takes 5 minutes to rebuild. Dave Originally Posted by N2 WeldingDid you rule out starter relay or solenoid?  Check for voltage at starter while attempting to crank engine?
Reply:Originally Posted by N2 WeldingDistributor has nothing to do with the starter.  Never heard that one before.
Reply:Originally Posted by smithdoorI agreeMost time the solenoid needs to rebuilt. Takes 5 minutes to rebuild. Dave
Reply:I swear that never again will I get involved in these threads.  It's like pounding your head against a wall, backing up, and doing it again.
Reply:Now your going to get John going
Reply:Originally Posted by BaTuOH! This is an Excellent Point!If you have a pre-'01 (and even some 01's), then you have a starter relay on the pass side fenderwell. Burnt contacts inside would do exactly what you describe. The easy test is to simply jump the two large terminals together (gonna spark some and will engage the starter motor) and if it cranks fast then you know your solenoid is bad...
Reply:Originally Posted by farmersammmI swear that never again will I get involved in these threads.  It's like pounding your head against a wall, backing up, and doing it again.
Reply:It could be the contact on solenoid or brushes even the wires going starter.Just a volt meter and find were voltage drops.Dave Originally Posted by motolife313The starter gear is engaging but turns the engine slow
Reply:Originally Posted by John TIts just classic moto.  Duhhhh …
Reply:Originally Posted by motolife313John got his supply and feed
Reply:First things first charge both batteries unhooked from the truck. Then take them to get tested. If they check out good and you think it's the starter take it off and have it tested. If thats good check the solenoid and all the wires going to batteries,grounds, solenoid and starter. If one battery is bad replace BOTH, not just one. That will kill your one good battery you didn't replace.Sent from my SM-N950U using Tapatalk
Reply:Originally Posted by motolife313I’m starting to think it’s the starter. It has been turning over kinda slow for a while and real slow the last few few days. Maybe the 1 dead battery and only 1 starting it killed the starter
Reply:Moto, it’s probably the starter, and it was damaged by the bad batteries.Much good advice from others on this thread.Electrical components are designed to withstand a maximum current (amps). Electrical assemblies demand power in watts. When voltage drops (as with a bad battery), the current draw will increase in order to deliver the demanded wattage.when the current draw increases beyond the  designed max, components get damaged.So repeated starts with a bad battery can cause either the starter, the solenoid, the battery cables or all of the above to get damaged.Miller Trailblazer Pro 350DMiller Suitcase MIGMiller Spectrum 2050Miller Syncrowave 250DXLincoln 210MP
Reply:Did you check the air in the tires?Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I bet it's the ignition bearings
Reply:Originally Posted by InsanerideI bet it's the ignition bearings
Reply:Back in the days before recorded time, the starter solenoid or relay would bypass the ignition resistor going to the distributor.  I think that went the way of the dinosaur with electroninc ignitions.
Reply:Originally Posted by N2 WeldingDistributor has nothing to do with the starter.  Never heard that one before.
Reply:Moto............... this is the last I gotta say on the matter  https://www.freeasestudyguides.com/e...%20read%20zero.Quit messin' around, and do a proper test.  It's about as easy as falling off a log.
Reply:Check the big 4/0 wire that leaves the passenger side battery and heads to the starter, The cable assembly on these trucks does not last forever, if there is corrosion on that 4/0 cable you can bet it runs several inches into the end where you can't see it and you can have brand new fully charged batteries but not enough current will reach the starter. The cable assembly is discontinued by Ford and choices are aftermarket which AFAIK only 1 company makes and real pricey, or make your own. As far as all the talk about the solenoid, 2001 has a fender mounted solenoid which only costs a few bucks, starting in 2002 it went to an ice cube relay under the dash.As far as battery replacement, always replace both batteries at the same time with the same batteries in a dual battery system, even the owner's manual will tell you that.Last edited by bigb; 05-13-2021 at 10:15 AM.Miller Challenger 172Miller Thunderbolt AC/DC 225/150Miller Maxstar 150 STLVictor 100CVictor JourneymanOxweld OAHarris O/ASmith O/A little torchNo, that's not my car.
Reply:Originally Posted by bigbAs far as all the talk about the solenoid, 2001 has a fender mounted solenoid which only costs a few bucks, starting in 2002 it went to an ice cube relay under the dash.
Reply:Originally Posted by BaTuNot to nit-pic But he says he has an '01 and some '01's do have that starter relay under the hood, and some don't (post #18 & 21). I think everything else's been said before, not sure it's getting through though...
Reply:I guess....But that's why I tell people that there's no such thing as a 2001 wiring diagram, figure out which version you have and use either a 2000 or a 2002
Reply:These are my pet peeve. If I saw them on a truck it would be the first thing I'd fix.Next I'd check that your alternator is charging at an idle.A bad alt will with batteries not fully charged will ruin your starter.Lincoln 350mpmiller regencymiller syncro wave 300
Reply:you guys realize you are talking to the wall right?Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.