Pickup will not start, only clicks?

BILL WHITEHEAD

MEMBER
2002 CHEVROLET SILVERADO
5.3L
V8
2WD
AUTOMATIC
128,000 MILES

When the key is switched to start the starter clicks and sometimes it starts to turn the engine but stops. Battery voltage drops to about 8 volts while starting but returns to 12.25 volts. I have replaced the starter with a refurbished starter and the same thing happens. I placed a good battery from another pickup in there and the same thing happens. I measure 8 volts on the starter and 5-6 volts on the control lug while trying to start the engine. I have checked for codes but there are none listed. All dash lights are normal but dim while in the start position. Not sure what to do next.

Thursday, May 29th, 2025 AT 2:32 PM

3 Replies

KEN L

MASTER CERTIFIED MECHANIC
54,137 POSTS

If the battery is good, it sounds like you have bad ground from the battery to the engine block, or you have a bad positive battery cable. I would inspect the cable for corrosion or internal bulging and if fund replace the cable, at the same time do the same for the ground cable. The ruck should also have a smaller ground wire going to the chassis near the fender. Please let me know what you find. Also go over this video, it can help as well:

https://www.youtube.com/watch?v=6YRW8fyNudY

Please go over this guide and get back to us.

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Friday, May 30th, 2025 AT 10:32 AM

BILL WHITEHEAD

MEMBER
2 POSTS

I had already watched the video. When I checked the voltage on the starter I did it by touching the 'starter' stud and the metal housing of the starter and got the same reading as the battery while trying to start. I also used the housing to get the control voltage reading. If either of the cables were high resistance or open, I would have read a lower voltage at those points. I pulled the starter relay and attached the 'output' to the battery + connection and got the same 'clicking' results, eliminating all the circuits in the cab (did not get voltage reading while doing this but I expect it would be the same). Is shorting the control stud to the starter stud is okay to do? Will it weld a wrench by doing that? The only other thing I can think of is to remove the serpentine belt in case the compressor/alternator/idler/etc, is frozen. I will try this next time I get a chance (truck is located 10 miles from me). I am trying not to have to remove the starter and have it checked which is the other option I can think of.

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Friday, May 30th, 2025 AT 5:42 PM

KEN L

MASTER CERTIFIED MECHANIC
54,137 POSTS

Yep, you can short across the main starter lug and the smaller trigger terminal. The starter should work, also I would remove the serpentine belt and "bar the engine over to make sure the starter is the problem, please go over this video to see how:

https://www.youtube.com/watch?v=oN42gZN6gOE

Please upload a video in your response.

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Saturday, May 31st, 2025 AT 10:24 AM