Starter Issues... Help!

1988 F250 7.3 -Original owner.
I'm perplexed, could sure use a little direction here; this is getting worse- I turn the key to 'start' I get a strong click that sounds like it's coming from my one year old rebuilt starter... like the solenoid gives one strong click with every turn of the key to 'run'.
Both batteries are strong!
I replaced starter relay with a new relay and even the old relay... same problem.
If I jump the two large relay terminals with a screwdriver 'sometimes' it'll crank but mostly it'll just a click.
I removed the 'S' wire and check with a test light and turn key to run... it lights bright every time.
Does the 'S' terminal absolutely need a solid and minimum 12v???
Check 'S' wire with a meter after GP burn 11.70v at the meter.
If I use a remote-trigger-starter hooked to the two large relay posts it'll crank and start.
if I use the remote-trigger-starter from the left terminal to the battery + it'll crank.
Faulty solenoid on the rebuilt starter???
Or, something going on with a wire down to the solenoid???
Technically rebuilt starter is two months out of warranty however, the store will warranty it for me.

My key stopped working but I could start it by jumping the solenoid posts. So I replaced the contacts slider board in the steering column. Not a fun job. And still no go. I gave up and wired in a push button. Sorry. That's all I've got.

S ( small wire) on relay is just a trigger,
it excites the relay .
11.7 "should " do it.
try a hot 13v directly from the battery to the s terminal on the relay.
Check for awesomely clean grounds and tight attachments.

Jumping across the 2 big lugs bypasses the relay sending power to the solenoid on the starter.

You can check out the wire to the starter for low resistance and clean terminations.
Smack the starter with a hammer while turning the key, treat it like a chevy
And report back, cuz then its column time...

Clb said:

S ( small wire) on relay is just a trigger,
it excites the relay .
11.7 "should " do it.
try a hot 13v directly from the battery to the s terminal on the relay.
Check for awesomely clean grounds and tight attachments.

Jumping across the 2 big lugs bypasses the relay sending power to the solenoid on the starter.

You can check out the wire to the starter for low resistance and clean terminations.
Smack the starter with a hammer while turning the key, treat it like a chevy
And report back, cuz then its column time...

Click to expand...

Thanks for all that... earlier today I 'believe' I did use the remote-starter from the + battery to the 'S' terminal and it did crank... I'll try that again tomorrow.
I 'believe' the 11.70V at the S-plug was because that was during a GP burn on a cold engine.
What I can do is 'if' I get the engine running, go out for a drive to bring-up engine temp and then retest the 'S' plug again for voltage as the GP's will instantly cycle off not drawing down battery voltage.
Years ago I did install a new ignition cylinder... way back in 09 I had to replace the actuator (cast part) down in the column... not fun.

Brian VT said:

My key stopped working but I could start it by jumping the solenoid posts. So I replaced the contacts slider board in the steering column. Not a fun job. And still no go. I gave up and wired in a push button. Sorry. That's all I've got.

Click to expand...

Many years ago I did replace that 'slider' switch down on the steering column that the long key rod connects to. I did adjust it for a solid engagement.
Being every time I tested the 'S' plug with the 12V test light with the key in the 'start' position and it lit-up I don't believe or hope something else in the column is the issue.

HammerDown said:

way back in 09 I had to replace the actuator (cast part) down in the column... not fun.

Click to expand...

When the engineers were designing that actuator they should've looked at the finished product and instantly realized that there ought to be a better way.

Ford had a better idea, then fell asleep!

Where is Indadesert when you need him, to reassure us that Ford engineers were the all knowing and made the most perfect product ever

Update... as I somewhat suspected, the solenoid on the starter must have been bad but, it had me thinking the fender mounted relay was at fault or maybe something in the wiring.
Replaced the starter with another reman and it's cranking like crazy > > > hopefully this reman lasts longer then the prior.