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I have an 87 f350 460 that iv had for a while now that i have went through a couple starters and firewall solenoids on and cannot figure out the problem. i have replaced the battery and cables as well. every once in a while the starter will drag hard when you go to start it up hot. once the engine cools down it is no longer an issue. cannot find any ground issues at all. also sometimes the solenoid sticks and continues to crank even with the key in the off position even after disconnecting the s wire...i just smack it with my key and it stops. i have seen others have this issue and never quite figured it out. also just recently the engine(when hot) is difficult to start and when does start only does so when you let off the key. i noticed my truck does not have the I wire from the solenoid to the coil as others iv had had. this could be the issue but if the truck didnt come with it from the factory and iv never had this problem before im not sure what it could be. any ideas anybody? maybe the two problems are related...
There are quite a few threads about many of the issues your having that can be searched on the site.
You simply must change the solenoid switch that has partially welded contacts.
It sounds like the excessive amperage has cooked that switch.
The normal high amperage load to the starter is passing through those cooked contacts.
You simply must start out with a clean load circuit.
Your control circuit, from the key to the solenoid switch, is likely not an issue.
Consider, (some you may have) all new cables from switch-to-starter, battery neg.-to-block and battery positive-to-switich. Properly routed and clamped in factory locations.
There are also posts about timing, grounding directly to starter bolt, poor quality starters, etc.
Access the control panel and click on "search forums", when in there add "1987- 1997 trucks" for the forum and "titles only" so the threads are for what you want.
the cheap starter could be the issue. thats all i can come up with. it is most definately excessive load on the circuit but i just havent figured out where. i have added grounds, changed ground locations, ignition timing is spot on...all i can actually come up with is the starter but have never had a problem with these starters in the past. unless this engine is higher compression than i know about but turns over just fine. I will keep digging tho, thanks