Starter won't engage

[Rattler12]

12.4 volts  at the battery. 12.4 volts at the starter from battery hot. 12.4 volts going into the ignition switch module at both connections. 10.4 volts at the s terminal on the solenoid when the ignition switch is turned to start and solenoid will not trigger. ?    Fusible link ?   Starter/ solenoid engages when out of the vehicle with 12 .4 in from the battery and grounded to the battery then jumped with remote start switch. Everything else works from the ignition switch from acc to run. New starter/solenoid/ignition switch

[hatzie]

Not a fusible link.  You have full battery volts at the ignition switch.
Hail Mary Shotgun parts swapping cost way more than a repair needs to.
10.4v means you're loosing volts between Circuit 2 feeding the ignition switch and the starter Crank lug.
I see you have a 5 speed.  Was it an automagic before?  Any modifications to the starter interlock switch wiring are suspect.
Still have the Neutral safety or added the clutch interlock switch?  Check your volts at the neutral safety switch or clutch interlock plug with the key turned to crank.  It's usually a Purple or Yellow wire from the ignition switch Crank position and purple out to the starter.  If you have full volts there jumper the plug and test whether it'll crank.  If it cranks replace the switch.  If it doesn't repair the wiring.

[bd]

In addition, a fully charged battery will measure 12.6 volts, so if your voltmeter is accurate the battery is a little low on charge.  Aside from that, verify battery cable condition and starter ground by connecting your remote starter switch between B+ and the solenoid "S" terminal.  Connect your voltmeter positive (+) probe to the positive post of the battery and the negative (-) probe to the 3/8" battery cable stud on the solenoid.  Measure the voltage while attempting to crank with the remote starter switch.  Repeat the process with the voltmeter (-) probe connected to the battery negative post and the (+) probe connected to bare metal on the starter frame.  In both cases there should be a maximum of 0.3 volt drop.  More than that, replace the cable(s) and/or repair the poor connection(s).

[Rattler12]

It was a 3 spd manual before and PO had removed the neutral safety switch and butt joined the yellow and purple wires together. I suspect this may be the problem as this happened once before but apparently mysteriously fixed itself as the truck started shortly after the first time it happened. Will check out that joint. Dumb question ....was there a starter interlock switch on manual trans trucks and if so where is it?

Have not added a clutch interlock switch. . Also have connected a remote starter switch between the 3/8 bat connection lug on the solenoid and the S terminal lug. Nothing happens same as with trying to use the start position on the ignition switch. Reason says a direct connection between those two would bypass anything in the ignition circuit and at least kick the solenoid in ?? Reason is not prevailing here.

I thought maybe by some far outside chance there was a ground problem between starter and motor/frame/body  and even ran a separate ground wire from the front mounting stud on the starter itself to battery ground......zero effect

[hatzie]

It was a 3 spd manual before and PO had removed the neutral safety switch and butt joined the yellow and purple wires together. I suspect this may be the problem as this happened once before but apparently mysteriously fixed itself as the truck started shortly after the first time it happened. Will check out that joint. Dumb question ....was there a starter interlock switch on manual trans trucks and if so where is it?

Have not added a clutch interlock switch. . Also have connected a remote starter switch between the 3/8 bat connection lug on the solenoid and the S terminal lug. Nothing happens same as with trying to use the start position on the ignition switch. Reason says a direct connection between those two would bypass anything in the ignition circuit and at least kick the solenoid in ?? Reason is not prevailing here.

I thought maybe by some far outside chance there was a ground problem between starter and motor/frame/body  and even ran a separate ground wire from the front mounting stud on the starter itself to battery ground......zero effect

The manual trucks used a starter interlock switch on the clutch pedal.

Fix the loose butt splice but that's not the problem now.

You have a battery ground to alternator bracket to engine connection problem....
or
Battery hot to starter lug connection problem.



My Droid from orbit

[Rattler12]

It was a 3 spd manual before and PO had removed the neutral safety switch and butt joined the yellow and purple wires together. I suspect this may be the problem as this happened once before but apparently mysteriously fixed itself as the truck started shortly after the first time it happened. Will check out that joint. Dumb question ....was there a starter interlock switch on manual trans trucks and if so where is it?

Have not added a clutch interlock switch. . Also have connected a remote starter switch between the 3/8 bat connection lug on the solenoid and the S terminal lug. Nothing happens same as with trying to use the start position on the ignition switch. Reason says a direct connection between those two would bypass anything in the ignition circuit and at least kick the solenoid in ?? Reason is not prevailing here.

I thought maybe by some far outside chance there was a ground problem between starter and motor/frame/body  and even ran a separate ground wire from the front mounting stud on the starter itself to battery ground......zero effect

The manual trucks used a starter interlock switch on the clutch pedal.

Fix the loose butt splice but that's not the problem now.

You have a battery ground to alternator bracket to engine connection problem....
or
Battery hot to starter lug connection problem.


Would this not also prevent lights, radio, horn etc from working? They work fine
My Droid from orbit

[hatzie]

It was a 3 spd manual before and PO had removed the neutral safety switch and butt joined the yellow and purple wires together. I suspect this may be the problem as this happened once before but apparently mysteriously fixed itself as the truck started shortly after the first time it happened. Will check out that joint. Dumb question ....was there a starter interlock switch on manual trans trucks and if so where is it?

Have not added a clutch interlock switch. . Also have connected a remote starter switch between the 3/8 bat connection lug on the solenoid and the S terminal lug. Nothing happens same as with trying to use the start position on the ignition switch. Reason says a direct connection between those two would bypass anything in the ignition circuit and at least kick the solenoid in ?? Reason is not prevailing here.

I thought maybe by some far outside chance there was a ground problem between starter and motor/frame/body  and even ran a separate ground wire from the front mounting stud on the starter itself to battery ground......zero effect

The manual trucks used a starter interlock switch on the clutch pedal.

Fix the loose butt splice but that's not the problem now.

You have a battery ground to alternator bracket to engine connection problem....
or
Battery hot to starter lug connection problem.


Would this not also prevent lights, radio, horn etc from working? They work fine
My Droid from orbit

Not neccesarily.  Lights etc don't draw many amps...  the starter does.  Lots of amps...

High amp draws make marginal connections stick out like a sore thumb.

My Droid from orbit

[bd]

...have connected a remote starter switch between the 3/8 bat connection lug on the solenoid and the S terminal lug.  Nothing happens same as with trying to use the start position on the ignition switch.  Reason says a direct connection between those two would bypass anything in the ignition circuit and at least kick the solenoid in ?? Reason is not prevailing here.

I thought maybe by some far outside chance there was a ground problem between starter and motor/frame/body  and even ran a separate ground wire from the front mounting stud on the starter itself to battery ground......zero effect

Clean the battery cable connections then connect your remote starter switch between the battery positive post and "S" terminal of the solenoid and give it another try.  The voltage drop measurements will tell you immediately if the problem is in the battery cabling.  If the engine cranks, reconnect the voltmeter across the battery posts and measure the battery voltage while cranking.

[Rattler12]

Found A problem and very well could be THE problem.  Took the starter off to bench test it again and the solenoid kicked in and spun the starter. On a hunch I took the front plate off to check the "brushes" and one of the spring clips that puts pressure on the brushes to hold them against the armature was broken in half and had fallen out. One half of it had an arc burn on it so may well have caused a direct short .....Hecho in Mehico...... Hope this is it.

[bd]

Any evidence of commutator pitting or burning?  A broken spring could cause a brush to skip and arc and might result in an open, especially if the bushings are worn too.  I take it there were no voltage losses across the cables?

[VileZambonie]

Found A problem and very well could be THE problem.  Took the starter off to bench test it again and the solenoid kicked in and spun the starter. On a hunch I took the front plate off to check the "brushes" and one of the spring clips that puts pressure on the brushes to hold them against the armature was broken in half and had fallen out. One half of it had an arc burn on it so may well have caused a direct short .....Hecho in Mehico...... Hope this is it.

Sounds like you need to replace the starter. It also sounds like you have a dead cell in the battery. When you go to get your new starter have them load test the battery

[Rattler12]

Problem solved. Replaced the starter and she started right up. Thank you gentlemen for your advice . I certainly appreciate it. Can't help but wonder why that spring clip broke in half.........oh well the mysteries of life. Miller time !!!!