I have an starter sticking issue with my 1991 f250 (302/5speed/4x4) which seems to be common problem with older fords. The truck was given to me by my step dad who used it as a fuel truck on the farm and in the 14 years he had it there was never a problem where the starter would stay running when you went to start it. I got it this spring and right after that the original starter solenoid gave up and would just click and not engage the starter. I replaced that one with a napa solenoid and almost every time i went to start the truck the starter would stick. The truck has since sat until a month ago when i finally had time to replace the clutch. i also put a brand new starter (because the mounting tabs broke off the original) and a brand new solenoid but it still sticks . However, if i jump the posts on the solenoid with a screwdriver it does not stick and i also don't think its the ignition either because it shuts the power off to the rest of the truck and kills the motor but not the starter. Anybody have an idea of where to check next? Should i maybe try a better quality solenoid? As of right now I am lost and any help would be greatly appreciated.

 

What posts are you jumping? The two large ones? Or the battery to the smaller start/ignition terminal. If it's the two big ones then the solonoid isn't being used. Jump to the small terminal.

The new solonoids are crap. I run a marine type terminal on my battery with a wing nut so I can remove the negative wire without tools if I need to just in case.

 

i was jumping to two large posts on the solenoid. That marine style terminal actually sounds like a good idea.



UPDATE: i just went out and jumped the smaller terminal to the positive battery post and the starter did not stick.

 

Your best bet would be to get a genuine Ford solenoid. When a solenoid unexpectedly sticks and keeps cranking the engine, giving the solenoid a few karate chops will likely unstick it.

 

Try some new cables.
Ground, starter and battery to solenoid.
They are old and don't owe you anything.
Clean the terminals and use some terminal protector or silicone grease when you nut the cables on.

Resistance in any part of the circuit causes higher current to pass through the solenoid contacts.
Enough amperage, and the contacts will melt together

 

... and replace your solenoid (again) because it really sounds like it's what's sticking. But as ArdWrknTrk says, if you just replace the solenoid and you have other problems you are likely to mess up the new solenoid right away too.