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This morning I took the batteries in and had them load tested by 2 parts stores both times both ok. I pulled the inspection plate on the transmission and could see that the starter bendix was not returning. Having had my fill with the China gear redux I replaced it with the factory piece...

An update for what appears to be slight progress. I confirmed that I am getting the same drop at the Diamond terminal under the hood that I see at the fuse panel in the cab when the key is in the on/run position. Knowing that the glow plug system is also engaged for starting I wanted to...

Mistaken1 and Warthog: Thanks for the update - I really appriciate your time on this problem. I managed to get a few measurements taken before it got dark tonight, but can see that thinking the way you did in your last reply is what it will take to solve this problem. I would have probably never...

Yes, very good diagram. So the sparks I made could have only been @ 12V? Measuring this voltage at 0 now can not be what it was before hand, or I would have got no sparks.

I have now loosened the starter bolts agian. No improvement. I still have 24V at main starter feed. Solenoid does not recieve any voltage when attempting to start. Solenoid will not engage or activate starter when fed 12V or 24V directly. I am measuring the 12V on the fuse panel at the fuse...

I have confirmed that I have 12V on both sides of the diamond lug for the engine harness. I did not expect to see 12V here. I also have 24V at the adjacent glowplug relay. So into the cab. At the fuse panel I have 12V. HOWEVER, when the ignition switch is turned on (not start) the voltage drops...

Starter Relay swapped, no change shes still dead.

I am going to check the starter relay tomorrow under the dash. I have a back up that I will swap. Great advice mistaken1, I'm guessing I wont fail to practice this in the future! The terminal that contacted the firewall was positive. (+)

The truck has been starting and running great since the problem in this thread was resolved: http://www.steelsoldiers.com/cucv/72149-sudden-no-start-tm-says-replace-starter.html Today I slightly re routed the starter solenoid wire to gain more clearance to the exhaust. I then jumped it to the...