i have been working on a 89 ford truck that has starter issues. the truck belongs to my neighbor. after the truck starts the starter continues to crank. he didnt realize it right away and drove it. he burned up the starter and ruined his battery. after replacing the starter he tried to hook up the new battery and he said it sparked. i ohm checked the solonoid and found the contacts fused. after starting the truck one time after replacement the contacts fused again. he tossed a bunch of parts at it and it still does the same thing. heres a list.
2 starters
ignition switch
new battery
3 new battery cables
5 solonoids 3 differant brands.
my question is if its got good power and good grounds what could be causing the contacts inside the solonoid to keep fusing?
hardly any voltage drop between the battery and the solenoid. the battery is brand new and the cable between that and the solenoid is 10 inches and brand new as well. I even ran a extra ground to the engine block the starter and the solenoid. same result. Im not sure what else to try. maybe use the solenoid as a relay and install a newer style starter with a solenoid on it to split the load on the contacts???
As i said before. Low voltage to the solenoid pull in coil. That is the small 18 gauge wire
that comes from the ignition switch. What voltage to that wire ? What voltage to that
wire when the ignition switch is calling for the starter ? That is the ONLY thing that will
cause that problem. Your looking at the wrong wires.
ok. now that we are on the same page. i checked voltage at the s. terminal while cranking. it was only 7.5 volts. checked output voltage at ignition switch was same thing. replaced switch again thinking loss of 5 volts was through switch. started truck same thing happened again. so i decided to use that wire to trigger a relay to activate solonoid. truck started several times and starter did not stay on. for curiosity sake i measured voltage drop through relay. was a little over 1 volt. started truck several times throughout the day with no issues. put the truck back together to put it outside and the dumb starter stuck again. im about ready to buy this truck from this guy. just so i dont have to work on it any more.... any other ideas???
The wiring diagram for that is from the battery to the ignition switch to the neutrol safety switch. where are you losing power ? If you don't check every inch of that circuit
you will NEVER fix this. It worked fine when it was new at the dealership. Good luck.
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starter issues 89 f250
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