Hi guys. If I could interject a comment of great value, you might consider adding a wire that you can run into the cab and connect to a digital voltmeter or a test light so you can see what is happening when the problem occurs. An easy point to start at is the ballast resistor on the firewall, under the hood. It is usually fed with a dark blue wire, but on some truck models that was a red wire. If you have the older dual resistor, the two terminals on one end will be connected through a short jumper wire. That is the end that gets 12 volts from the ignition switch, and is a good place to start. Run the wire from that resistor into the cab, but be careful that it is run in such a way that it won't get cut by the hood. Knowing whether the light goes off or stays on when the engine stalls will tell us which way to move to next.
If it's easier, you can connect the test light to the dark blue, (or red) wire on the alternator too.
The second wire at the starter you were asking about is to run the built-in starter solenoid. When you turn the ignition switch to "crank", it turns on the very small current that turns on the starter relay. The starter relay turns on the medium current, (about 15 amps), that turns on the starter solenoid. The solenoid has two functions. First, it electro-mechanically moves the starter's drive gear out to engage the ring gear on the torque converter which is bolted to the engine. Second, once the drive gear is engaged, the additional movement of the solenoid turns on the very high-current switch that passes current to the starter, (about 150 - 200 amps). That solenoid wire is usually light or dark brown and is considerably fatter than most of the other wires on the truck.
Monday, December 11th, 2017 AT 3:37 PM