I have an 89 full size broncoXLT. I recently had the engine rebuilt and i relplaced the starter. well when i put the relay on next to the battery it made my new 70.00 starter hang. so i put the old relay back on and it worked fine. I exchanged the relay and keeped it in my truck until the old one went out completely. Last night i tried to put the new one on and it made my starter hang angain. has anybody else had this problem and if not can anybody offer me some advice on what to do if i need to change that relay one day.

 

Sounds like perhaps you have a faulty relay. If it clicks over but doesn't send juice or ENOUGH juice down the line to the starter, you will have problems. If you are uncertain, check the resistance across the two big posts with an ohm meter while the relay is energized. Check the old one, then check the new one. If the resistance is much higher on the new one than on the old one, there's your problem.

I just finished replacing positive battery cable in mine because of this problem. The cable showed NO signs of deterioration and my meter showed 12.74 VDC everywhere it should have. However, when I checked the resistance through that chunk of #4 cable, it showed 95.05 ohms! So I replaced it with a new cable (0.27 ohms resistance). No probelms since. The problem was discovered after I removed the old cable and found it had corroded from the inside out.