OK, lemme see if anyone can give me some info. I cooked my starter and had to rebuild it so I can use it while I await a new one to arrive from the states. After a complete dismantling of it, I soldered a few internal wires together that had melted, reassembled it and it spun up fine. Then I had to fix the arm that is magnatized to the body when power is applied sending the gear into the flywheel. Are you still with me? The contact that the arm hits and breaks open had melted off and I spliced a different one in it's place. Now I'm having problems getting it to acuate. Sometimes it does sometimes it don't. How close should the arm sit in relation to the contact and or the body? The shield holds it in place but there is no way to adjust it after it is on. My battery is fully charged to 12.75 volts. What does that contact do??? When everything works as advertised it is open (no contact), when power removed it is closed (contact made). Any advise on adjusting this darn thing??? I'm so close to getting it running!!! I can't be without wheels for two weeks!!! My original problem was a bad starter solinoid that refused to quit, and ate the gear drive on the starter...

 

Apparently I know more about rebuilding starters than most! They're not that hard to do, I bet the majority of folks replace them when they could have rebuilt it themselves. No big deal, my new one will be here in a few days...

 

I haven't torn many Ford starters apart. So I am not sure about the contacts. I do know as serious as some of the problems you have with your starter are, that it doesn't sound hopeful. Unless you had replacement windings to install, I don't give it much hope. I think I would buy some spare parts for your truck to keep around if you need your truck that bad. How many Ford trucks are over their in Spain?

 

Franklin2:

Your right about it being too far gone to save. Over here I have nothing by way of parts. I have been very happy with good old NAPA for nuts and bolts kind of stuff. I usually get it to me with in 10 days. Incedently, the starter was the LAST item on my motor that isn't brand new after the rebuild! Go figure.

D from Spain