Starting Trouble... Solenoid, starter.......?

[ferrall]

1994 5.8L Fi PMDA.

Had intermittent starting issues for a while where I'd turn the key and get nothing. Decided to tap on the typical Ford 4 terminal solenoid and voila...it started. Continued to test it each time I got nothing after turning the key and everytime I tapped the solenoid it started. My theory was I needed a new solenoid so I bought one and installed it. Turned the key and I got nothing. Switched from battery 1 to battery 2 and then I got chattering from the starter like you get when your battery is weak and can't fully turn the starter. Load tested battery 1. Didn't really pass but didn't have any issues previous. Load tested battery 2. Held but was weak. Put it on the charger. Went out and bought a new battery 1. Hooked it up and same thing....chattering of the starter. Pulled the starter and got it tested. Passed. Now, I have no I idea or what to do next except install the old solenoid and see what happens. Please help! Thanks!

 

[bruceb58]

Take all the cables off everything and clean to bright shiny metal. That includes your battery negative terminal and its connection to the block.

 

[ferrall]

I already checked all the connections and even gave them a thin coating of lithium grease. Even if I did have a bad connection that wouldn't explain why I can tap on the old solenoid and have it start but it won't with a brand new one. Also, what is the difference between solenoid numbers? They all look the same. If I use the OMC number (985064) off the original part I get a certain aftermarket part number and if I use the Volvo part# (3853839) off iboats' store I get another.

 

[bruceb58]

Including the negative terminal between the battery and the block? The solenoid get's its ground through its base. If you have a bad ground somewhere, That can be your issue.

I hope you aren't putting lithium grease between the cable and where its mounting.

 

[ferrall]

Yes. I have 1 ground cable for each battery going to the block at separate points. I understand having a ground issue can be a problem but why is it that I could get it to start with the old solenoid but not with the new one? And the sound that the starter makes is more of a hammering than a clicking sound.

 

[muskyfins]

The hammering sound is the starter not getting enough amperage to turn the motor over.

As Bruce said, not lithium grease. Must be dieletric electrical grease/battery terminal grease.

FWIW-I have gotten brand new Ford starter solenoids from the delaer that were no good. I'd check elsewhere first, but this has happened.

 

[ferrall]

I'm going to go over my ground cables again but as I'm doing that are there any other grounding wires/cables I should check. My battery cables are very accessible so it's easy to see if there is corrosion. Also, what if I take just my number 1 battery (number 2 out of the loop) and ground it to a totally new, clean spot? Will this solve the theory of improper grounding being the issue if the starter still doesn't work? Because all the cables and connections to the starter and solenoid are clean.

 

[ferrall]

Ok, so I checked all my grounds from battery to engine. Even though they were clean I polished them up and put some dielectric grease on them. Same result. Starter hammering. Switched to both batteries and it hammered then started. Back to the one battery and hammering. This is all with the new solenoid. Put the old solenoid back in and turn the key and nothing. Tap the solenoid and it started over and over. Then even once it started without tapping. I'm at a loss.

 

[Fishhead-1]

Have you tried jumping power from hot terminal on solenoid to the switch terminal?

 

[ferrall]

Yes I did. It starts when you do that. That aside, I was brainstorming this morning in bed and decided to check voltage on the 12v signal wire from the ignition to the solenoid. Got only 6v. Ran a new wire and it starts like a champ everytime and that's with the old original solenoid