I have just replaced the starter since it went out last week, i tried making a makeshift fuse with existing fuse and a paper clip, paper clip burnt thru as well. Starter bolt is slightly loose which i will tighten that up. My friend says it sounds like a wire is either rubbing somewhere or there is a short. My next question is, would the short be in the ignition itsself or would it be because of the starter being loose?

 

Which fuse is this?

The 10 amp fuse only supplies the trigger side of the starter relay going to the clutch/neutral safety switch

The 50 amp fuse supplies the starter solenoid (attached to starter itself)

 

It's the 40Amp fuse under the hood in the fuse compartment. The one that connects the starter and ignition. I went and got a brand new fuse and it still popped. I had starting issues about a week ago and had to turn the key about a thousand times to get it to start, dont know if that would be the issue, i started it last night to go to work, it ran a about maybe 30 seconds normally, i went back inside to grab my lighter and the truck just died, shut off. As i didnt know what had happened til this morning, when i noticed the fuse was blown. My friend says it might be the wire coming from the starter up to the fuse that might be either worn and rubbing, or it may be exposed and arking?

 

If the wire is damaged at all it can cause issues. 40Amps is quite a bit of power so this wire is expected to heat up and expand. Any expansion on a wire that is not kept in check can cause the resistance to spike and do wonky things. Get the bolts tightened all the way first. If the ground side is bad you can't ensure anything. The main power doesn't flow through the ignition. Just the control side.

 

What year truck is this?

The 50 amp starter fuse does not touch the ignition circuit at all, and should only have a draw on it when the key is in the 'start' position.

There are a number of 20 amp fuses for the PCM, Auto Shutdown Relay, fuel pump, etc.