The problem: Starter failures on Ford Diesel Trucks from the 1994-2001, F-250, F-350, F-450, F-550 and Ford’s Super Duty models.
Workhorse trucks, such as the Ford Super Duty and F-series, are often subject to off-road and rigorous conditions which can lead to dirt, rust and corrosion on the engine block. Any time you replace a starter on these vehicles make sure the engine block is cleaned where the starter is mounted. Pay special attention to the front of the starter where corrosion can occur. If corrosion on the starter is particularly bad, then it will certainly be worse on the engine block.
Keeping the mounting surfaces on the starter and engine block corrosion-free is crucial. The area where the starter mounts to the engine block is part of the starter’s ground circuit. If the ground circuit connection is corroded this can be the reason the starter failed to start. Having a poor ground connection can also cause internal starter components to be damaged.
Below are two photos that show the condition of a Ford truck starter that was returned for warranty.
In closing, always pay particular attention to the amount of rust on both the starter and engine block when servicing trucks such as the Ford F-series and Ford Super Duty vehicles. If the starter fails on these vehicles corrosion may be the culprit. Remember, a clean engine block will help ensure a good ground connection when installing a starter.
If you have additional questions regarding starter installations please call our tech support hotline at 1-800-228-9672.