My 2000 EXP has been sitting for a year or so due to a crack plenum at the water crossover tube. 5.4

Got it all back together and it cranked up on the first shot. Unbelievable especially with almost 300K on the ticker.

Only problem was that there was a terrible metal on metal grinding sound coming from the passenger side of the motor. I thought it was just some crud in a pulley and would work it's way out. Revved the motor a little and heard a "ting" and the noise went away. Idled like it was brand new. Went in to clean up and move vehicles out of the way for a test drive and the starter wouldn't hit. Removed the starter and it was burned up. Could smell that the magic smoke had been let out. Only conclusion was that the original starter hung and finally gave up the ghost.

Ordered a new starter and wrestled that SOB back in to place and have the same sound. Woried, I shut it off because I didn't want to burn up another starter. Decided that maybe the bendix wasn't retracting all the way so I made some shims out of washers. Still no good.

Anyone else have this issue or fixed it? Thanks.

 

Maybe the starter relay is what's hanging and not dropping power to the starter.