Starts and runs fine when engine is cool. After truck has run and is warm (not even all the way up to normal operating temp) or if the ambient air temp is above 70 deg F, the truck won't crank. All dash lights work normally, battery is fine, starter tested fine. Once the truck cools down and the ambient air temp is below 70, the truck cranks, starts, and rums fine.
It is possible that the solenoid on the starter binds when the starter is hot. When you say that the starter was tested, was it tested hot?
Does the starter click when you attempt to start it? When you turn the key, the switch energises a small relay, which in turn energises the solenoid, which in turn applies power to the starter motor.
The solenoid should make an audible sound when it pulls in the plunger.
If you have a second person, one could turn the key, and another could gently hit the solenoid with a rubber or plastic hammer. This worked on a Dodge minivan that I had.
An image of the plunger is available at
http://www.amazon.com/Starter-Solenoid-Rebuild-Contacts-Intrepid/dp/B00COOB298
Testimonial: "Tested old starter and replaced starter while warm... same problem. Checked all fuses and relays. No codes stored. All connections are clean and tight. No click or any sound when I turn the key. I had a second person hit the starter and solenoid while I turned the key. It wanted to catch a few times, but not enough to turn over."
If it contacted a few times when you hit it, it still sounds like the solenoid.
This can be easily tested. Place a meter or test light on the small solenoid wire and you should see if you are getting the start signal. If that works, move the light to the output of the solenoid. The start signal should make the solenoid click and 12 volts should be passed to the stater motor.
Also put the test light on the feed wire from the battery - the voltage should remain high, or the light bright when you attempt to start it.
I had one vehicle that I was sure that the starter was bad. I rebuilt the starter and solenoid, bench tested it, and everything was good. When I replaced it into the vehicle, the starter still would not turn. I was not very happy. I actually removed the starter and bench tested it again - it worked perfectly.
To make a long story short, there are two wires going into the positive battery cable on a Dodge. the smaller one feeds all systems for the vehicle except for the starter. The large one supplies the stater through the solenoid. On this vehicle, the large wire was badly corroded inside the battery terminal, but looked great before I opened it up.
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