This past Friday evening I hopped in my truck which at the time was stone cold. When it fired up I heard a slight unfamiliar sound from the engine bay. I blipped the pedal several times and thought the sound was gone. In that the engine was cold and making the typical cold engine noisy racket which helped mask the continuing problem, I drove less than 2 miles, parked the truck and twisted the key off but the engine continued rotating very unevenly for about 30 seconds. The engine wasn't firing but was still rotating. By the time the engine ceased rotating, smoke began rolling from under the hood along with an acrid smell of something electrical failing. I raised the hood and inspected with a light, but didn't see any indication of melting or dripping. My next guess was the starter, as I did try to re-start it but there was no response from the starter.

It was too dark to get under the truck so I left with plans to return the next day and inspect the starter. That follow-up inspection of the starter showed signs of heat, some melt and stink. I've removed the starter and am waiting for the replacement starter to arrive. The disappointing factor is this starter is 11 months old. I installed it in April 2017. I purchased it from a Ford dealership, and it is a starter for a 6.4 Powerstroke.

The black protective cap that covers the battery cable and solenoid wire terminal studs was still on the starter at the time of failure. When I removed the cap, it was dry inside. I did a continuity test of both the solenoid wire and battery cable in case they may have chafed one another, and there was no indication they were contacting each other. What are your opinions as to why the solenoid remained stuck in the cranking position?

David

 

It's mechanical, it's happens. Not sure it can be diagnosed for sure without seeing the starter.
It's too bad it's not that old, my advice would be get a unit from the salvage yard. If you look around on places like car-part.com I've seen them for $100.

 

At the time of the starter still engaged, disconnecting the connector we use for cranking the motor over rather then the key would have told if it was a starter fault or a circuit fault. Either would cause a continuing engagement.

I would think it's possible the solenoid to stick engaged, either through the solenoid itself or the drive mechanism for the engagement. If the contactor disc stays against the posts current will continue to flow.

 

 

[QUOTE=TooManyToys.;17869919]At the time of the starter still engaged, disconnecting the connector we use for cranking the motor over rather then the key would have told if it was a starter fault or a circuit fault. Either would cause a continuing engagement.

Absolutely, however by the time I first attempted to shut it down with the key, the starter was nearly melted down. There was a tremendous amount of smoke escaping from the yet unopened hood, so much so that I feared flames would erupt any second and my truck would plunge into a total melt-down. At that point, opening the hood and reaching into the engine bay to twist the starter connector wire in the dark of night with billowing smoke, wasn't even a thought.

David

 

I understand completely David, and probably I would be in the same place. Not judging. I was trying to prod you in case it happens again.

If it's a circuit issue, not sure if it's an all the time or key position problem.

 

OK, good advice since I now know the symptoms of this type breakdown.

Immediately after installing the new starter, I'll have my wife twisting the ignition key while I'm standing beside the truck, hood open, in case I have to ****** the starter cable apart.

I'm also a proponent of fire extinguishers; one in the Cobra, two in the car hauling trailer, two in the garage and one on each level of the home. But, I need one more as insurance for my aging dinosaur diesel.

David

 

What version of Cobra do you have?

 

It's the 427 SC, FE-powered. Just a pretend Cobra, a replica I've owned for 24 years. The most fun was driving the heck out of it on a few road race courses. Decided to stay off the road courses when my first engine let loose; and then there's the aging thing where my response time and reflexes have changed.

We trailered it to the SAAC 42 event last year at Indianapolis Motor Speedway. Got to lap the course there a number of times. Side pipes blasting off the grandstands was crazy cool.

 

 

One easy thing to do is disconnect the starter solenoid wire up be the passenger firewall righ near the fan.
Take a meter and check for voltage with the key turned to "RUN" If you are seeing 12V then there is a problem
and most likely it's not the starter that was the issue.

Also I am willing to bet that For dis going to want to look at the truck so they can say that is was the starter or the control circuit,

 

Gentlemen, I appreciate your input!

Thanks Yahiko, I'll check for voltage there.

David

 

The starter was the problem.

David

 

 

You are so right. I had dug away 5" of snow to get under the truck. It was snowing lightly during the repair. I checked for voltage getting to the solenoid with KOEO, and there was none. After the installation I had the under hood starter wire positioned in case I had to jump out of the truck and tug it apart. Was kind of holding my breath when I twisted the key to the start position, and then life was good again.

David