Starting Problem 1995 T100

[Surf WRaX]

So I've done a lot of reading, and done a lot of things, but after about 4 months or so I keep having the same starting problem.

It's the one click starting problem where you hear the solenoid click but the truck won't start. Keep trying and it will start.

First I cleaned the battery contacts and checked wires. This made me think I fixed it as it ran for 2-3 months no problem.

Then it hapenned again and I pulled out the starter and replaced the solenoid contacts. I thought for sure that was it as the old contacts looked bad but 3 months later same problem.

Then I replaced the battery, that was Oct 2007, almost 6 months ago. Ran like a charm. Now I have the problem again. (Edit: this time it seems even weirder where I can turn the key, hear the click, and keep holding the key turned for up to 5 seconds or so until it starts. The whole time during this it is silent, not trying to turn over, just sitting there until wham it starts like nothing is wrong)

So what's next, I've read:
- replace starter relay
- rebuild starter and solenoid
- replace neutral grounding switch

Any advice welcome. So many people say the contacts fixed their problem but for me it didn't last.

[BamZipPow]

Posting piccies would really help as it may show something yer missing.

Pull the starter and post piccies of yer contacts...that could tell us a lot. You could also take yer starter to AutoZone and they will test it for you. That could possible eliminate anything to do with the starter. If is not the starter, I would look at ALL the cables.

How good are the starter cables? How good are the battery cables? How good is that ground? Those would probably be the easiest to check/clean/tighten/replace.

[Surf WRaX]

I'm starting to think perhaps I should of swapped out the plunger in the Solenoid when I did the contacts. I talked to a rebuilder here and he said that is probably my problem.

As far as the starter, battery, and ground cables, they all look good to me, but I don't know what to look for. They are all wrapped in plastic and hard to inspect every inch of the cable. Any tips on that?

[BamZipPow]

Did you clean up the plunger at all? At least the mating surface of the plunger? How good was the shaft and plunger spring?

You could probably put a meter on the cable when it's disconnected on both ends and test the resistance. Visual inspection of yer cables is the typical things...frayed, corrosion, broken wires. Obviously...if the cable/connectors have too much resistance...yer not gonna git full current flow. Unless you've had a leaky battery that wicked the acid into and corroded the cables, it should be good...

[Surf WRaX]

The plunger was pretty toasted. It was shaved down and pitted and discolored. I replaced it and the contacts (again, although they weren't bad after being in there for 9 months or so) and so far things are starting fine. We'll see how it goes after another 6-12 months. I might also try getting replacement battery cables, if I can figure out where to buy those.

I got my truck year wrong, it is a 1997.