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Well I will say I have never had this problem before. This week my starter had issues disengaging after the motor starts. Essentially once the truck fires up I can still hear the starter engaged for maybe 5 seconds, and this morning it didn't disengage for about a minute. I'm guessing the starter is getting toasted when this happens and is destroying the gear. I will say its less than 4 months old and was a brand new, not reman from Napa. Paid close to 280 for it.
I am going to take it back under warranty, and hope its just a faulty solenoid, but after failing to disengage a dozen times, I want a new one.
I was also thinking the solenoid block up on the inside of the fender might be going bad? I am going to replace it anyways, but wanted to open the floor up to hear if any of you guys have had this issue. I have never had it happen on any vehicle I own, so this is a completely new problem for me.
I will point out too the other day, I tried to start it and forgot to take my chip out of no start so I turned the key off, and it kept cranking away. Turned the key back on and clicked the chip out of a no start setting and it fired up, but the starter still stayed engaged. The problem started before this instance, but man it was weird to have it cranking with the key off. Really sounds like the solenoid block on the firewall...
From my experience that would point to a starter relay (since you already replaced the starter), or an ignition switch.
I had the same issue with an older Ford. Starter stayed engaged and burnt up. So I replaced it. I had same issue and went to starter relay, that didn't work. I then went to ignition switch and it was fixed.
That being said I would save the ignition switch until last and try the relay first.
Chances are no matter what caused the problem the starter is toast. Chances are it it went on very long it may have damaged the ring gear as well. Both gears are not designed dot run engaged for extended periods and at high (relatively speaking) speeds.
That's a relay on the fender. Easy enough to test. Put a voltmeter on the wire that goes down to the starter, have an assistant turn the key and release it. If there's still voltage at that terminal while the starter continues to run, then indeed the relay is sticking. If no voltage, then it's the starter.
Well I tested the relay, tested out fine. I notice the plastic housing aroound the relay internals had started to crack, so I replaced it anyway. Still no change. It decides to do it more so when cold out, say 15-35 degrees, and when its above 45 it rarely is happening. Hope to get her pulled tonight and take it back in to get a new starter. Dam thing is 3-4 months old at that. The only two 3 parts on this truck that are non FORD OEM, are the starter, stancor relay, and Jim's injectors. Last time I buy a non Motorcraft starter for this piece.
Well I replaced the relay...didn't help. I ended up taking the starter back and they switched me out a new one for free. I have not had problems yet.... Been about 5 days now.
Seems to be more prominent when it was cold and we are going to be into the single digits tomorrow night so that should be a good test...
I am all about OEM motorcraft parts till the stealership quoted me(take a stab) for a new starter!
bendix? mind explaining, starter was 280 from Napa more than 55% less than the motorcraft from the dealership. It was a new starter and not a reman... surprised the ring gear looked new when I took it out considering it stayed engaged more than a couple dozen times for longer than a minute.