Wire getting crispy
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
Wire getting crispy
Small wire leads to starter solenoid is getting very hot and crispy.
1986 f250 4wd auto 6.9l When I try to start the truck the small wire pictured gets very hot. This is the negative terminal of my main battery and the small wire goes to the starter solenoid. I am wondering if it is a bad connection just being under the terminal post or if something else is going bad.
I have an air intrusion problem and the fuel drains back to the tank so I have to crank a lot to get it started. this wire gets hot almost immediately. I cleaned the terminals recently and sprayed them with anti-corrosion spray so the top of the battery is covered with over spray.
i ain't rite
Joined: Mar 2005
Posts: 65,447
Likes: 5,517
From: Marlboro Mental Hospital.
if that small ground wire is getting very hot when cranking, i would have ot say you have a dirty ground connection either on one of the main battery cables, or at the starter to block joint itself.
Logistics Pro
Joined: Jun 2017
Posts: 3,948
Likes: 509
From: Edmond, OK
Andy, if all of your battery cables look like that it's time to replace them. My battery cables were crispy like that so I broke down and replaced them. Best $90 I spent on the truck. The starter pulls ALOT of current and needs good cables and clean connections to work properly. Even parts store cheapies would be better than those old, fried ones.
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
Andy, if all of your battery cables look like that it's time to replace them. My battery cables were crispy like that so I broke down and replaced them. Best $90 I spent on the truck. The starter pulls ALOT of current and needs good cables and clean connections to work properly. Even parts store cheapies would be better than those old, fried ones.
Logistics Pro
Joined: Jun 2017
Posts: 3,948
Likes: 509
From: Edmond, OK
More than likely the smoking wire was caused by excess resistance since the cables are old and crispy. You can always take your starter to an auto parts store to be tested, but I bet new battery cables will fix your problems. It will start easier and you won't get anymore smoking when the starter draws a ton of current. 
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
More than likely the smoking wire was caused by excess resistance since the cables are old and crispy. You can always take your starter to an auto parts store to be tested, but I bet new battery cables will fix your problems. It will start easier and you won't get anymore smoking when the starter draws a ton of current.
Logistics Pro
Joined: Jun 2017
Posts: 3,948
Likes: 509
From: Edmond, OK
I recently had battery cables built for my truck and I used 00 gauge welding cable. The pigtails that connect to the starter relay can be about 12 gauge.
Trending Topics
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
I am making new cables. I am on my second attempt at soldering a new terminal to the 4/0 positive cable. I want to crimp and solder the connection. Crimping is easy, I just squeezed it in my bench vise, just enough to hold. how do I solder the connection without melting the insulation on the wire? I am googling but not much luck so far.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
i ain't rite
Joined: Mar 2005
Posts: 65,447
Likes: 5,517
From: Marlboro Mental Hospital.
slide a 6-8 inch piece of heat shrink tubing down the cable. tin the connector, then crimp it. then it will be easier to solder. once done, trim the burnt insulation off the cable and slide the heat shrink tubing over the connector and exposed wire and heat it to seal over everything.
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
I am making new cables. I am on my second attempt at soldering a new terminal to the 4/0 positive cable. I want to crimp and solder the connection. Crimping is easy, I just squeezed it in my bench vise, just enough to hold. how do I solder the connection without melting the insulation on the wire? I am googling but not much luck so far.
Logistics Pro
Joined: Jun 2017
Posts: 3,948
Likes: 509
From: Edmond, OK
Andy, that's good that you figured out how to solder the terminals.
You can get battery cable crimpers. I considered building my own cables but I just used an electrical supply company recommended by a friend.
Let us know how it starts.
You can get battery cable crimpers. I considered building my own cables but I just used an electrical supply company recommended by a friend.
Let us know how it starts.
Logistics Pro
Joined: Jun 2017
Posts: 3,948
Likes: 509
From: Edmond, OK
Andy, since Ray mentioned misgivings about the solder job you did I will also mention that I've heard that battery cables should never be soldered. The starter motor draws ALOT of current. The high current and heat that made your old cables crispy can also cause solder joints to fail. I was reluctant to mention it earlier but you can take or leave my advice. 
Fleet Mechanic
Joined: Sep 2016
Posts: 1,519
Likes: 224
From: Nevada
Last Friday I had the negative drivers side cable made at NAPA. Used 1/0 gauge wire, and they crimped on the
ring terminal ends. On the Battery side Iam using a battery clamp with the threaded stud and Wing Nut.
Napa used a crimper you beat on with a hammer, something like this one.
4 yrs ago I had CARQUEST in Santa Cruz make the battery cables for the Pass side. They used some long
handle crimper pliers. something like these. It`s a UK site but you get the idea.
https://www.autoelectricsupplies.co....0/category/304
Some good info on proper lug/ring terminal ends and proper crimps.
https://marinehowto.com/making-your-own-battery-cables/
I use to think soldering was the way to go, but did some reading, and crimping is better.
Charlie
ring terminal ends. On the Battery side Iam using a battery clamp with the threaded stud and Wing Nut.
Napa used a crimper you beat on with a hammer, something like this one.
4 yrs ago I had CARQUEST in Santa Cruz make the battery cables for the Pass side. They used some long
handle crimper pliers. something like these. It`s a UK site but you get the idea.
https://www.autoelectricsupplies.co....0/category/304
Some good info on proper lug/ring terminal ends and proper crimps.
https://marinehowto.com/making-your-own-battery-cables/
I use to think soldering was the way to go, but did some reading, and crimping is better.
Charlie
Thread Starter
|
Mountain Pass
Joined: Feb 2016
Posts: 124
Likes: 5
From: Jeffersonville, IN
It seemed to flow very well. I applied the heat to the connector and applied the solder to the cable and let it run through the cable strands, basically filled the connector completely full of solder. There is about a two foot length of solder melted in there. The cables I replaced were soldered. If I have done it incorrectly, it won't take long to find out. As of now, nothing seems to be getting hot. I am pretty much clueless so I welcome all feedback and truly appreciate all the help I receive from this forum. You guys/gals are the best.