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Username Post: Intermittent Starting        (Topic#374603)
highway star 
Poster
Posts: 62

Loc: North Mississippi
Reg: 10-09-18
03-01-24 10:44 AM - Post#2867435    

1994 Silverado 5.7L bought new. Been getting a click at the starter. Replaced battery, battery cables, starter, alternator. Sometimes it cranks & sometimes it just clicks. What else is in the starter circuit that could cause this? Thanks!



 
someotherguy 
Senior Moderator
Posts: 29771
someotherguy
Loc: Texas
Reg: 08-01-03
03-01-24 11:40 AM - Post#2867438    
    In response to highway star

You've covered all the major suspects. I'd have suspected the starter solenoid first, providing you ensured the battery was fully charged and in good condition. Cables would've been next.

It's not likely based on the symptom but all you've really got left, IMO, are the wire from the ignition switch to the starter solenoid, and the ignition switch itself - down low on the steering column. The electrical portion, not the tumbler.

If you're handy with a multimeter you could ohm out the wire between the connector at the switch, and the solenoid. Might be damaged somewhere along the way, best guess would be where it goes down the protective tube on the passenger rear of the engine (bolted to the bellhousing) before it reaches the starter.

Just an offhand thought/long shot, where is your main battery ground attached? Intake manifold like factory.. or accessory bracket? Is it possible that ground is flaky? Paint on the intake or bracket cutting down contact area, excess thread sealant on the intake stud if gaskets have been replaced, etc.?

Richard

06 Silverado ISS / 06 Silverado SS / 06 300C SRT8 / 93 C3500 dually


 
highway star 
Poster
Posts: 62

Loc: North Mississippi
Reg: 10-09-18
03-01-24 01:06 PM - Post#2867441    
    In response to someotherguy

Battery ground on intake, all clean there and on the right inner fender. So, 2 battery grounds. Will check the ignition to the solenoid wire(s). Thanks



 
bobb 
Super Senior Member
Posts: 6607

Loc: paradise
Reg: 09-05-03
03-02-24 10:57 AM - Post#2867465    
    In response to highway star

battery should ground to block or starter on bare metal. small start signal wire is a common failure. wire gets old and resistance builds up. or so it seems. i have upgraded many of these wires and sometimes adding a relay close by. voltage drop testing will tell the story.

70 L camino, grampa engine, g-force 5 spd, road rage suspension. Pray first before all else fails.


 
highway star 
Poster
Posts: 62

Loc: North Mississippi
Reg: 10-09-18
03-02-24 04:59 PM - Post#2867480    
    In response to bobb

"Small Start Signal Wire"? Where does this wire run?
And the battery ground cable is originally grounded to an intake manifold stud on the passenger's side. Should I find a better place? Whereabouts?
Thanks for the help.



Edited by highway star on 03-02-24 05:02 PM. Reason for edit: No reason given.

 
bobb 
Super Senior Member
Posts: 6607

Loc: paradise
Reg: 09-05-03
03-03-24 10:38 AM - Post#2867504    
    In response to highway star

front face right lower part of block may have unused bolt holes. small wire on starter is too small. i use 12 gauge or bigger.

70 L camino, grampa engine, g-force 5 spd, road rage suspension. Pray first before all else fails.


 
someotherguy 
Senior Moderator
Posts: 29771
someotherguy
Loc: Texas
Reg: 08-01-03
03-03-24 01:56 PM - Post#2867514    
    In response to bobb

  • bobb Said:
battery should ground to block or starter on bare metal. small start signal wire is a common failure. wire gets old and resistance builds up. or so it seems. i have upgraded many of these wires and sometimes adding a relay close by. voltage drop testing will tell the story.


While you're not wrong bobb, the factory location for the negative cable on these particular trucks is on an intake stud directly to the passenger side of the thermostat housing. Providing the cable is good, fasteners are tight, and there's no paint or sealer reducing contact surface, it shouldn't be an issue.

Pic is from an ugly engine bay, but original layout of the cable on a '94 5.7 (this is one of my pics from doing intake gaskets around 158K)

I absolutely agree though that condition of the negative cable and connection, and wire from ignition switch to solenoid are important. In my experience these trucks don't have an undersized wire, never had to repair/replace one, other than physical damage.

Richard

Attachment: rh94_int12.jpg (2.31 MB) 3 View(s)




06 Silverado ISS / 06 Silverado SS / 06 300C SRT8 / 93 C3500 dually


 
bobb 
Super Senior Member
Posts: 6607

Loc: paradise
Reg: 09-05-03
03-05-24 08:22 AM - Post#2867568    
    In response to someotherguy

ground to block is an upgrade. same for bigger wires.

70 L camino, grampa engine, g-force 5 spd, road rage suspension. Pray first before all else fails.


 
highway star 
Poster
Posts: 62

Loc: North Mississippi
Reg: 10-09-18
03-28-24 04:16 PM - Post#2868389    
    In response to bobb

I repositioned the battery ground to block, no joy. Sometimes it starts, sometimes it doesn't. I still need to look closely at the purple wire. Does the starting system (schematic) have a relay in it?? Thanks.



 
bobb 
Super Senior Member
Posts: 6607

Loc: paradise
Reg: 09-05-03
03-30-24 10:34 AM - Post#2868444    
    In response to highway star

not sure if there is a relay. i would add one no matter what. i like big ones like https://www.wastebuilt.com/v23232-a0001-x003-was te... i just replaced my ford type relay with one that has the push button on top. along with a 10 gauge wire to the starter its overkill.

70 L camino, grampa engine, g-force 5 spd, road rage suspension. Pray first before all else fails.


 
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