Ran into a bit of a problem, and I'm hoping to find some advice. I have a 95 f series (f450). It's been running ok, but then I started to loose power intermittently, and then it started dying on me while driving. I was always able to start it up again, until a few days ago. Since then I replaced fuel filter, (air filter seems fine based on indicator). I also replaced the batteries as I was getting low voltage reads on the ones that were on there. Once I replaced the batteries, I was able to get it to turn over again but not start. It came close but never fired up fully. Then the starter began to smoke. I think the starter is completely toast now, because there was a lot of smoke and I can't turn it over at all now despite having sufficient battery power. Here are my questions: 1) Can I just replace the starter solenoid, or is there likely another part of the starter motor that is now compromised? 2) What else should I be checking that may have led to the starter failing and loosing power up to this point? Bear in mind it was otherwise running quite well. The few days leading up to it not starting it did take a few more attempts to turn over, but it always fired up and ran well once going. The turbo whistle sounds good too. Thanks in advance!

 

Since you let the smoke out of the starter, you will need a complete new one. When trying to start it is important to crank for 30 seconds and then let the starter cool for a couple of minutes before cranking for another 30 seconds. These starters generate a lot of heat, which results with burning the insulation off the wires. (the magic smoke)

 

Of course, it is also possible that the starter is the instigator of all your troubles. When the brushes are worn out and they don't make good contact anymore, it gets hot. Then if the solder lets go on one brush, it will only turn over slowly. At that point there is great potential for smoke.
Hope the starter resolves it all!

 

Agreed, replace the entire thing. Superduty offset is quite a popular upgrade.

 

clean your block grounds while in there, made a big difference on mine with starting.

or do this for peace of mind

https://www.ford-trucks.com/forums/1...ou-cranky.html