Starter will not turn or disengage

Tiny
NICK82
  • MEMBER
  • 1996 FORD F-150
  • 4.9L
  • 6 CYL
  • 2WD
  • MANUAL
  • 150,000 MILES
When the truck would start the starter wouldn't disengage. Replacing the starter initially at least turned over and catch the flywheel. After awhile, it would just make a winding in grinding sound as if the flywheel and starter where clanking or something was over speeding but not catching. Replace the ignition switch and ignition key lock (that was fubar anyways) and replaced the solenoid. Tried again, and same thing. So dropped the three month old starter and seen it was fubar as the Bendix would slide up and down easily. Put a new starter in and first time it started fine but didn't disengage. So tried second time and starter did disengage like it was suppose to. Tried third time and back to the winding/grinding sound but no catch so I'm pretty sure that starter is now toast though the battery is at roughly 11 volts but the starter acted strong. After removing the old starter, the teeth on the flywheel looked fine. Also metered the the line from the solenoid to the starter and it read 10.7 volts only when the key was switched to the start position otherwise got 0 volts. The two heavier wires on the outside of the solenoid has constant voltage regardless if the key is even in the ignition and the voltage matched the battery voltage (which I don't know if that's good or not). I Just do not know what's going on. Any suggestions?
Sunday, February 10th, 2019 AT 1:39 PM

7 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good afternoon.

First, you need to either charge the battery or replace it.

As far as the starter, when you turn the key to start, you said you have voltage. When you release the key, does the voltage go to 0?

Roy
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Sunday, February 10th, 2019 AT 1:53 PM
Tiny
NICK82
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I went ahead and did put the battery back on the charger. Yes, on the solenoid to starter wire it does go back 0 volts after you release from the start position.
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Sunday, February 10th, 2019 AT 2:16 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Okay, good.

Is the shim there between the starters and the bell housing? Each time you remove the starter, there should be a shim that comes out with the starter.

Roy
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Sunday, February 10th, 2019 AT 2:23 PM
Tiny
NICK82
  • MEMBER
  • 6 POSTS
No, there wasn't any shims that came out when the starter was dropped. I want to be sure if that year and model required shims or not?
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Sunday, February 10th, 2019 AT 2:45 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
I believe it did. It would make sense since the Bendix is getting stuck in the flywheel.

It is going too far in.

I am concerned that there may be damage to the flywheel now from all the issues.

It does not show a picture of the starter mount.

Roy
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Sunday, February 10th, 2019 AT 2:49 PM
Tiny
NICK82
  • MEMBER
  • 6 POSTS
Could a faulty ignition module be causing the problem? I know it's supplying voltage to the relay like it should, but I don't know after extended time it's failing while connected?
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Sunday, February 10th, 2019 AT 4:01 PM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
No, that controls spark only. Has no connection to the starting circuit.

Roy
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Sunday, February 10th, 2019 AT 4:03 PM

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