For the last couple of months I have had issues with my Starter Solenoid and I figured I would share my experiences on here.

First it started when I replaced the original solenoid when I replaced the starter. The first replacement from advance lasted about a month.

Turned the first one in on warranty. The second was dead out of the box. Got it replaced. The third lasted about a week before i had to start beating on it with a screwdriver.

I have read that with cheaper solenoids the contacts will melt and stick not allowing power to pass through to the starter.

My current solenoid came from NAPA. It felt heavier and better built than the one from advance. So far so good no issues.

Lesson learned= Parts with lifetime warranties have them for a reason

 

Thanks for sharing. Lots of guys on here pick up Motorcraft solenoids from the salvage when they see them. Those units seem to have a better track record.

 

You can't go wrong with the ones I mentioned here https://www.ford-trucks.com/forums/1...l#post13475092

 

I'm glad I haven't had any solenoid problems. My truck still appears to have the original solenoid. It's a Motorcraft part and the fading of it matches the fender.

 

After my original starter solenoid failed (stuck on) I went through three more in short order, two of them NAPA Golds.


After reading up on the problem I came upon an interesting theory, that being the battery cable between the battery and the solenoid corrodes and breaks down internally over time and the added resistance of the corroded cable causes more draw through the solenoid which causes it to fail.


Don't know if that's true or not but after replacing the battery cable with a brand new extra heavy one the NAPA silver starter solenoid has held up.


But I still keep an extra one in the rig, just in case.


My 0.02c, YMMV.

 

A voltage drop test will tell you if the cables have excessive internal resistance. It is common for the cables to "have high resistance" internally and still look pretty good on the outside.

 

I think CB has it right.
Cables can get 'black' inside the insulation.
That, or a weak battery, corroded connection at the battery terminals, block ground, starter or solenoid.
Any of these can cause high current draw through the contacts.

 

Good cables are a must IMO.
I made a new solenoid to starter cable




And used the same size and construction between the battery and solenoid (no photo of that unless you want to see one).
And made new ground cables also.


It's one of the first things I do when I buy a new vehicle, after a full service.

 

Military lugs are a good thing Tom!

I cringe every time see someone post with one of those POS 'emergency repair' terminal clamps..

 

I'm a fan of heavy duty cable lugs as well.
This is an example, before adding the adhesive lined heat shrink.

 

You must have a REALLY nice crimper!

I usually buy copper lugs at the welding supply and solder them on with a torch.

Marine shrink tube with the adhesive inside is a must for me.

Where do you get your heat resistant sleeve for the starter cable?

 

There's a company called Thermotec that makes it.
Thermo-Tec

 

Tom - That link isn't working for me. Is it just me?

 

Works fine for me.

Why is it that most people can include no useful information when they turn in a problem report? Merely saying something like: "doesn't work" or "won't open" or "link is bad" offers absolutely zero help to the person who might fix it... they make him/her go try it for themselves and see if they can find a problem (Heaven help you if you don't provide a link to click on) which may or may not result in the same problem the OP is having.

But we have no idea wtf the OP's problem is bwecause all they say is it "doesn't work" instead of describing what it DOES do.

*sigh*

I'm real disinclined to go investigating reports like that.... if the person doesn't tell me what the exact behavior is when they perform some action (and maybe describe how that is different from the expected behavior) then I have to be pretty dang bored and tolerant of lusers to get involved...

 

If it went anywhere I would have said where it took me instead of where it was supposed to take me. But when I click on it the new page that opens goes nowhere. But you knew that.