I would check spark and fuel pressure at the no start situation. Here's a post I did a decade ago that explains how to check fuel pressure. Truck now has 440K and this specific issue has not happened since then...
Here you go:
Post #1067
I hammered (lightly tapped) the dust cap end while on the truck. Also you will need to grind down the center of the plastic center cap with a die grinder. Test fit with paint on the dustcap and fit center cap. No paint on centercap, good 2 go. Steve
Thanks,
Paint Code: Army Green 6v7 from 2011 trail teams FJ Cruiser with matching FN wheels in 17" version.
Sliders are welded on. Came with truck. Not sure brand.
Here's my take....
Questionable paint/body work. Back right quarter reflector area leading over to the rear sill looks to be bondo with bad body work.
Underside of hood looks meh. Probably other areas that the camera isn't picking up. No rear seating area pics?
Wiring loom to the right of the...
Exactly. The wire from the switch doesn't give the juice to engage the solenoid fully. Could be the switch, the wire to or from the switch. Done many of these Ford solenoid mods and still no issues at all.
About 9 years ago I installed the 90 degree filter adapter and still no startup rattle. Something to think about.
https://forum.ih8mud.com/threads/rattle-on-start-up.738525/page-2#post-9727226
I didn’t see where you had swapped out the positive battery cable.
Ok. Gotta be the starter. I purchased a high output one a few years back for our 94 at OReillys and that thing cranks so fast like none I’ve every heard. Highly recommend. It is smaller in size than factory, but gets it.
@Box Rocket
"I have bypassed the ignition by running a jumper wire directly from the battery to the starter as a way to check for a voltage drop somewhere between the ignition and the starter. When I do that the solenoid will click loudly and it sounds like the plunger is pushing the starter...
60 shipped. Started at 50 about 8 years ago. Material and shipping costs continue to go up. May be bumping up to 65 very soon. Thanks for your interest. Steve
Just to clarify, have you disconnected the grey NSS barrel plug located way up high driver's side engine block and inspected both inside (internal) ends for corrosion? Corrosion and internal connections cannot be visually inspected unless the plug halves are disconnected.
Unfortunately I've...
Not thinking a fuel filter would cause this. With that said it’s either spark or fuel related. If you have another person, try testing for spark when it happens. Spark plug tester lights work great and are cheap. Next would be to squirt some starting fluid through a vacuum/intake hose if you...