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1993 F250 XL 7.3 idi 5-speed Single Cab
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Discussion Starter · #1 ·
Background - Bought a 1993 F250 7.3 idi with almost 300k on the clock pretty rough body but drove really well outside of jarring your teeth out of your head. Had been somewhat of a daily drive for me and ran fine. Used it last weekend to do some pulling concrete foundation blocks and forgot how powerful this thing is. One the way back to the house she kind of felt like she was losing power (or surging)??? Anyway got it home and parked it. Went out the next day and she turned over but then started surging and died. Did some research and since I don't have records of when the fuel filter was replaced thats where I started.

Replaced the fuel filter, filled with Diesel Kleen through the holes and put it all back together. Tried starting (expecting to surge until I get the air out) but she never fired. Upon inspection of the filter, checking for leaks, I noticed some "drops" that I hadn't noticed before around the fender well. Since I was the only one home I set the phone up to record what was happening there while I cranked it and noticed there was some fuel spitting from somewhere. Finally found that the supply line to the fuel filter had a slit in it spitting fuel everywhere.

Replaced the line, thinking all should be good, but still expected some surging from air in the fuel system. Tried cranking for about 10 secs and would let off, let it seat for a few mins and then try again. It never fired. After a few rounds of this I let it sit for about 30-45 minutes. Coming back out when I bumped the key there was no sound (dings), no gauge movement, no clicks, nothing. OK may have drained the batteries, ordered a charger and let it charge the batteries back up in the evening and overnight.

This morning go out and charger is showing complete, volts are at 12.6+ on both batteries. Jump in and hit the key, and nothing at all, no headlights, no hazards, nothing.

By the way the key cylinder needs replacing I know because it spins freely without a key but I'm hoping that can be the last thing I replace as I would really like to get it running for now.

I've checked the stater solenoid (relay) on the passenger side and below is what I have found:
  • No key
    • Terminal 1 (from battery) - 12.6+V
    • Terminal 2 - 10+V
    • S Terminal - 10+V
  • Key in the "On" position
    • Terminal 1 (from battery) - 12.6+V
    • Terminal 2 - 12.6+V
    • S Terminal - 12.6+V
  • There is absolutely no spark or "bumping of starter" when I use a screwdriver to jump T1 and T2, regardless of the keys position.
  • I also tried running a jumper from the battery POS to the STerminal which seem to make no difference, still wouldn't arc/spark or bump the starter.
I have read some things about there being an aluminum piece that goes from the key cylinder to the ignition switch that can break or get stuck but I can't seem to locate that. I have take apart the steering column housing but no luck finding it. If it is there and someone thinks this is the issue can you point it out to me on the pic :) I must be blind.

I appreciate any and all help!
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1993 F250 XL 7.3 idi 5-speed Single Cab
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Discussion Starter · #3 ·
The part breaking in the column only applies to pre-'92 trucks, and it wouldn't interfere with jumping the starter relay, anyway.

Remove, clean, & tighten all 4 battery terminals.

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Thanks for the reply Steve83!!! After some more parts thrown at it (ignition switch) still nothing. Was getting 12+V at the fuse boxes but nothing in the cab and I finally gave up and just did the "ill just stare at the engine for a while and something will happen". And sure enough, I started double/triple checking the batteries. I had no issues with cranking this beast at all so I was at a loss. I had checked the cables the night before when I put the charger on the battery but I guess something happened that day when I was trying to crank it and it had in deed loosens the negative cable on one battery. It was still connected enough to provide voltage readings but was very loose in the clamp. I took it off completely and clamped it back down securely and reattached to the battery post and hit the key. Power everywhere!!! In fact the air intrusion from the slit fuel line didn't even cause that much "surging/burping" it fired pretty quick in fact. Hardly any white smoke at all and after a minutes was the high idle kick out and she just started purring no smoke at all, actually never really has smoked.

Did a short test drive and she did great, expect when I popped the hood after the drive (engine still running) diesel was spitting at me from yet another failed hose. This time from the Injection pump to injector #1(?, front driver side). It was the braided type fuel line so I grabbed one of the extra fuel lines I ordered the day before, replaced it and after driving into work today, there was no diesel leaking (at least not spitting at me anywhere). Next task is to perform a fuel return line kit replamcent and then start working on a glow plug issue.

Its a pain when something doesn't work, but man I love this truck, she's not that pretty to look at but for the most part simple to work on and with groups like this makes it almost painless :)

Thanks again!
 
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