My starter died on me last night without any signs. It was 11 months old. It started up perfectly and after I turned it off to run out of the truck for a minute, only single click from solenoid. I checked all the engine ground connections, replaced the solenoid, replaced solenoid>starter cable, checked the battery (13 V normal and 8-9 V while trying to start) and still one click. Most likely my starter and I need to replace it but before I go ahead I have few questions. I am running Hedman headers which hug the starter pretty close. Could that be the problem? As a matter of fact, starter positive terminal is less than 1/8" from one of the header pipes. Is it possible that the starter was killed immediately without signs because of this condition? I did not have any issues with hot starts and starts were immediate before. Should I use a blanket on the next starter or tape on headers? And what remedy can I have for the positive terminal being that close to the header pipe?

 

Had a 1970 Firebird with the starter located really close to the exhaust. Would always have to wait at least 10 minutes after shutting down for the starter to work. More recently, my 88 F150 just got another new battery. I had rur rur rur slow starting issues for over a year and was always worse when recently shut off. Finally left me waiting just like my old Firebird. The battery voltage was fine and it even checked fine with a Harbor Freight Load tester. However, my local alternator/starter guy checked the battery and found that although it was an 850 CCA battery, it didn't have all of that rating anymore. He said that some batteries quickly loose their full rating coupled with Fords 88 4.9l starter was the worst they ever built. So I can't comment on the 8-9 volts under load you saw (sounds low), but don't discount both the battery and the heat issue because they both give the same results... hard starting after recently shut down.

 

The headers on my truck fry a new starter within days....definitely put a "racing blanket" on it....also check your valve covers for leakage....sometimes oil can drip down and kill the starter as well.

 

My '83 with 351W and headers had this problem.

If I stalled truck out or did not let it sit for 15+ minutes it would not start.
I had to push start the behemoth (F250 4x4) a few times fooling around at stop lights and letting it stall out.

I would also say the heat did the starter in.

 

I would get a starter blanket and header wrap and use them as stated above headers can cook a new starter in days it happened in my challenger I got the header wrap and a starter blanket ftom hehe and never had a problem since I had the same issues after shutting off it would barely turn over seems like a dead battery but was actually just the starter getting heat soaked eventually it died on me so I got a starter and the blanket n wrap check out the thread on highboy short headers I posted a link of the parts I used

 

Found out the issue. Positive terminal at the starter was badly burned. Since I did mention that the positive terminal was too close to the header (<1/8"), I presume that this resulted in a short. I plan on wrapping that portion of the header in hotshield fiberglass tape and hope that it will have some insulating properties. In addition, I need to get some kind of a cap (plastic or rubber) to place over the terminal's 1/2" nut. Anyone have any suggestions where I can get something like that?

 

I unplugged one of the spark plug wires and checked against ground whether fiberglass tape has any conductive insulation. Verdict...nonewhatsoever. I am kinda stuck here with what I can electrically insulate my starter terminal from the header. This thing is 1/16" away from it. I need a suggestion on a high temperature, electrically non conductive tape or sheet that I can wrap the the header at the location. Any thoughts?

 

I have had the same problem on many of these old ford pick-ups, quick solution is the starter blanket and mark the header before removing it of where the bolt is, then after u remove the header take a ballpen hammer and dent the header tube in slightly, just enough to clear the bolt.

 

any kind of cap that you put on there is going to melt,jmo

 

Here is my plan: I noticed that there is a ~1/2" deep copper nut (#33923-S) between the wire and the starter body. According to the diagram here



this nut retains the stud. I suppose I can remove this nut and replace it with a 1/4" deep nut, cut the stud down and bring the assembly away from the header (given that the assembly is equidistant from the starter body). Then I will wrap the header with the fiberglass wrap and cover the terminal with a rubber boot. Its a pita to remove the starter, so I will have to do everything in place. Any possibility of this stud (#11102) falling into the starter body?

 

Have you thought about removing the starter and knocking a dimple in the header with a hammer to get clearance?

 

Sorry for the redundant reply. The gentleman above beat me to the punch.

 

+3.

Best, quickest, easiest solution. No, it will not effect how the truck runs. If you do not want to do that, it looks like you could just cut off the bolt about 1/4 inch and maybe also get a thin nut that fits. That would get you enough clearance for the stud. I would still put a blanket on the starter as well.