Well, the starter that was giving me trouble in the extreme cold about a month ago straightened up and worked fine, until today. I pulled into the gas station, got some gas, and then the engine turned once and then the starter quit and never worked again. I checked out my battery cables because they had a small amount of corrosion on them, so I cleaned them off and put them back on the battery. I left the key on and bridged the solenoid, it sparked, but the starter didn't even make a sound. I then tapped on it with a hammer, and the starter itself make a loud click one time when I turned the key over, and then nothing. I then had a guy who at the gas station turn the key while I was tapping on the starter, and some serious sparks flew out of the top front side of the starter until he let off the key. I figured this was bad, and I had to come to work, so I just pushed her to the side of the gas station and told them I'd be back tomorrow morning to pick it up. Does this sound like a new starter issue to y'all? What would cause sparks? Anything else I should check before I just get the new starter and bust my knuckles changing it out? Also, any advice on changing the starter? Thanks in advance, everyone!

Oh, by the way, it's a 1997 4.6. Thanks, everybody, I am up the creek right now, but at least it's the day after payday so I can actually afford parts!

 

Sounds like the starter is bad. I'd go ahead and replace it with one that has a lifetime warranty. The sparks could be a short in the armature, or the bushes, or any number of poor connections inside the starter. When you replace the starter, I'd go ahead and replace the solenoid, just to ensure that your new starter is getting the best connection possible. The old starter could've worn out the contacts, so best bet is a replacement of both. Also, check the cables through the full length for any melting of the insulation.

 

it could be a loose conection on the starter. pull on the wires and cables to see if any are loose or broken, they could be arcing. if all seems ok then its probably the starter.

 

Yeah, I pulled on all of the wires around the starter just to see if they were loose, and they all seemed ok. I'll check closer for melted insulation, and I will probably change the cables as well when I change it out. Now, when you say change the solenoid, do you mean the one attached to the starter? Any recommendations on starters with lifetime warranties? I'd planned on just using a Motorcraft starter, but do you think I can find a better one?

 

Any sparks that you are seeing outside of the starter is not starter related, more likely with the battery/solenoid connections/cables. The location of the starters on these vehicles is not great, receives alot of road splash. They tend to corrode up pretty bad causing all kinds of problems.

Regarding the starter not working, there can be a lot of potential issues if the battery/solenoid connections are okay. Again, you will not see any sparks come flying out of the starter due to any internal problems. At the very worst, you will short out the armature and melt the motor lead sleeve creating alot of smoke.

As far as corrosion problems, the solenoid on the starter is most likely the culprit. It sounds like it has trouble simply engaging and making the power connection. And then when you were able to have the connection made (loud click), no power was transferred to the motor.

The only other possibility of the starter motor not cranking over is an open circuit in the armature. Since this problem has arose before, I highly doubt it has to do with the armature; solenoid and cables, yes.

Ford dealerships don't sell solenoids so you will need to get an aftermarket solenoid if you go that route. Personally, I would replace the hole starter, yeah it is a lot more money. But since it is a '97, and depending on usage, the brushes could be going out. So in another couple of years, you might have to replace the starter anyhow. Visteon changed the design of the starter for the '98 model and up to have a lot more corrosion protection. They have also beefed up the armature assembly, especially the commutator. Worth your while if keeping the vehicle longer. There isn't a better starter for your truck than that offered from the dealer.

Regarding replacing the battery cable, that is a good idea. Go to a marine/boat supply store and pick up some marine grade battery cables. Will last a lot longer, have much less corrosion issues and give you a chance to upgrade the size of the cable.

Once you get back up and underway, coat your starter connections with sometype of non-electric, waterproof grease. I use Vaseline, not the best, but readily available.

 

I would agree with stormsearch as to replacing the items he listed. I will disagree as for the sparks from the starter. The sparks happened after hitting it with the HAMMER. You most likely broke the magnets around the armature. It is never a good idea to hit a starter with a hammer, as you will usually end up breaking the magnets. I have a buddy that has an auto electric place and he has shown me many starters ruined by hitting them when they could have been rebrushed or rebuilt cheeper than a new one. Anyhow it sounds like a new one will be needed for sure now.



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Sleddog made another good point, don't be rapping on the main body of the starter. If anything is sticking it will be the solenoid.

But, how sparks come out of a metal frame is beyond me. It just isn't possible unless the frame has a crack or large hole. Sparks cannot come from the armature assembly through the frame to the outside. If this was the case, there would be a lot vehicle fires anytime a starter had an internal short. It just can't happen.