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Posted by Chris Willsey on Tuesday, August 04, 2009 at 10:22:28 :
Ok, I have a problem with my 66 D200 that has me baffled.
After working with the truck all day a few days ago starting at least 10 times with out an glitch I went to my shop to work on a forklift. I shut off the truck at the garage door while I walked inside to open the door. When I tried to restart the truck there was a click and then nothing. No electrical at all. No lights or anything. I pushed the truck inside and came back yesterday to try and figure it out.
Here is what I have done and what has happened so far: Tapped on the started with a hammer, tried a new battery with almost 13 volts, charged the battery, charged the old battery, replaced the relay, replaced the ignition switch, cleaned off all starter connections and re-installed, pulled all the firewall plugs, brushed off, sprayed with electrical contact cleaner and re-installed (several times). Checked that I was getting full 12 volts all the way to the starter and that the ground was good. Tried to jump the starter polls with pliers (got a bump and a spark only once then nothing). No electrical works except periodically for a few seconds. I also plugged in a new ceramic coil resistor.
After I installed the relay and was across the room trying to get the cylinder out of the old switch to put it in the new switch the truck all of a sudden started turning over and the lights came on ( I had the light swath on trying to find the connection fault) so I ran over and pulled the positive cable off the battery. What had happened is when I installed the new relay there was a short to the starter energizer wire because there is so little clearance, but why it waited 10 minutes to start turning over with no one touching the truck is a mystery. So I fixed the short and then the switch and when I tried to start it again there was another bump and once again I had no electrical at all.
A few times during the whole process I have seen the fuel gauge activate when I turn the key to aux. but that has only happened a few times then it is dead again. Also the heater blower started working once because the switch was pulled out while I trouble-shot. Anytime anything has started temporarily working it is not while I am rattling a connector or doing anything logical. It just happens then doesn't work again. I disconnected the starter cables to see it there might be a short of some kind there zapping power but that made no difference everything else was still dead.
I guess the only thing left that I can think of is to replace the starter even though that makes no sense.
Up until this happened the truck has always started since I put it back on the road last summer. I have tried everything I can think of and am now at a total loss.
Anybody have a clew as to what might be going on?
Thanks for listening.
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