Originally Posted by TexasGuy001

There is a known issue with the spade terminal. It is recommended that it be replaced with a ring terminal to avoid bad connections.

Ford Starter Solenoid Spade Terminal

Originally Posted by Tedster9

Here's another favorite, shamelessly stolen. The windup on this one, some girl asked her friend to keep an eye on her dog while she was out of the country a few weeks. So, being a normal guy, decided to have some fun and sent her this pic. "Guess what we're having".

Originally Posted by Tedster9

^^^ This. As the voltage goes down, a device will draw more current. 20 years is a long time for copper cables, switches and grounds. I think maybe too there is some work hardening going on, and manufacturers seem to be using dissimilar metals that corrode all by themselves, too. Usually the cable size manufacturers use is just adequate for the purpose when new, but over time the corrosion through the system becomes significant as it is cumulative. It adds up!

It's a bitch to get at them, but it absolutely pays to clean ground points on newer vehicles, to include alternator brackets and hardware, ECU ground, weather-paks, SAE connectors etc. We already know basic stuff like this is required to keep the older stuff on the road. Stay out in front of the newer rigs before somethings expensives get roasted.

Originally Posted by Tedster9

^^^ This. As the voltage goes down, a device will draw more current. 20 years is a long time for copper cables, switches and grounds. I think maybe too there is some work hardening going on, and manufacturers seem to be using dissimilar metals that corrode all by themselves, too. Usually the cable size manufacturers use is just adequate for the purpose when new, but over time the corrosion through the system becomes significant as it is cumulative. It adds up!

It's a bitch to get at them, but it absolutely pays to clean ground points on newer vehicles, to include alternator brackets and hardware, ECU ground, weather-paks, SAE connectors etc. We already know basic stuff like this is required to keep the older stuff on the road. Stay out in front of the newer rigs before somethings expensives get roasted.

Originally Posted by luv2fly

Had similar problems with my '88 5.0 5 speed. PO had gone through starters, replaced the ignition switch, cap, rotor, solenoid, and just throwing NUMEROUS parts at it chasing the issue. I thought they had just replaced some components over the years as maintenance. Nope, they were chasing a starter that was constantly failing when I found the receipts.

The problem was in the starter cable, which was a cheapo Chinese Auto Zone unit. Fabbed one up with top shelf cable and connectors and soldered it all together. Haven't had a problem since, 100% solved.

Originally Posted by fightlivefree

I replace the cable too with Auto Zone part, Will check into it now. All the crap is Chinese parts

Thanks,

Larry

Originally Posted by luv2fly

I went an auto electric specialty shop where they rebuild starters/alternators/industrial applications, etc. Told them what I was wanted and they actually built the cable for me while I watched. Took the old cable it as a pattern and after I bought the components they offered to put it together. There was an obvious difference between the auto zone chinese crap and the unit they built. Plus, it wasn't much more than the chinese crap either. $15 maybe?