Starter problem... SAME OLD GRIND!

Fellow Super Duty Lovers... I need some HELP!!!
I just returned from Arizona (I live in Michigan) with the truck of my dreams: a 2001 F350 DRW Lariat Crew Cab with the venerable 7.3 Diesel... AND it has only 40,000 miles on it!!!
It's a one owner truck that sat unused - and unstarted - for over six years. Other than a couple of scratches and a few Arizona "sun spots", it's absolutely cherry! VERY COOL... except that periodically the starter doesn't want to engage the ring gear. At first there were no issues at all. Then on the drive back to Michigan, the grinding became more frequent. It's now to the point that I'm concerned about damaging the ring gear.
So here's what i've done so far: Removed the starter and disassembled it. My thought was - still is - that it's somehow related to the long idle time. I looked for ANYTHING that might cause the problem. The starter gears are ok, the solenoid functions properly, the flywheel ring gear looks good, electrical connections appear to be good (I installed two new batteries before leaving). I took the starter to my local parts shop and they ran a diagnostic - all ok. For what it's worth, it's the two-bolt model. Oh, I also replaced the ignition key cylinder which had some other unrelated issues.
So NOW WHAT??? And advice you might have will be really appreciated!

Off the top I'd say.. The Solenoid, although it functions (bench tests) properly.. it may have lost the needed torque to counter the return spring.. to fully engage the ring gear.. from sitting for 6 years ? Replace the soliniod ? Any shims ?

Joe

I am with Big Joe on this one. The starter solenoid is shot. Sitting around for many years does strange things to the electrical components. You night make sure all of your battery cables are clean and tight. This goes for the ground cables.

Dave

DaveBen said:

I am with Big Joe on this one. The starter solenoid is shot. Sitting around for many years does strange things to the electrical components. You night make sure all of your battery cables are clean and tight. This goes for the ground cables.

Dave

Click to expand...

Thank you gentlemen. I really hate replacing stuff on a process of elimination basis... especially when it comes to electrical components since they usually can't be returned. However, I tend to agree with you both. The good news is that the solenoid is a lot less expensive than the starter. Stay tuned... I'll let you know what happens.

You will need access, at least, to a good scanner for further diagnostic work. At least access to someone who has a scanner. This will save you more money than every one, here, guessing what maybe wrong.

Dave

Thanks Dave... As it turns out, I DO HAVE a scanner! It just never occurred to me that it might be useful in diagnosing this kind of problem. I'll dust it off today and see what it says.
Onanother note, I see that you have installed a "fast idle switch". I've heard about them but don't know what they are used for. Can you enlighten me?

This is a switch that engages the PTO fast idle when it is turned on. The engine goes up to 1200 rpm until you turn it off or put it in gear, or hit the brake. Nice for cold weather to get heat going inside the cab.

Dave

Thanks Dave... maybe I'll consider ordering one next time around! Unless, of course, it's available on the aftermarket. If so please let me know.
As to the continuing saga of the grinding starter... it looks lilke the starter solenoid was the problem afterall. That's the good news. The BAD news is that the solenoid is only available when purchased with the starter - at least on the two bolt starter that I happen to have. $189.95 later, I'm back on the road!!! And live continues to be good.
Now my challenge is to get my "new" humanga-truck ready for the Michigan winter! I'd really prefer to put it in hybernation until spring but that's not an option, or so my wife tells me. As soon as I finish installing some new updates - and I'd like some PSD reader suggestions here - I plan to coat the entire under carriage with Eastwood rust preventive coatings.
Later...

Mine is home made. Later models can get and use Outfitter Switches for high idle and other things. Good luck with winterizing!

Dave

Fink, you just need to take that starter to an automotive electrical place and get it rebuilt.