I have recently performed some work on my '93 Ford F-350 IDI. I had disconnected the negative battery cables to complete the work. During the work I broke off a stud/terminal on the starter relay and therefore disconnected the only wire(red) on this terminal. Being somewhat of a novice at repairs I relanded this red wire on the other side of the relay(i.e. essentially bypassing the start circuit...bad move I know) where there a lot wires landed. After completing the other repairs I went to reconnect the negative battery cables to both batteries. When I connected the passenger side battery cable I heard some clicking from the engine(starter?). I then tried connect the drivers side battery cable and heard alot more clicking and a bunch of sparks which startled me enough that I let go of this cable so it is now resting on the terminal. Not knowing what I tried to undo what I just did by removing the cables. I successfully removed the passenger side cable but when I try to remove the drivers side cable I get lots of sparking and the starter wanting to crank! I have tried to remove the red wire I mistakenly landed but I also get sparking just by loosening the nut that holds it down.

Any advice on what I can do here to get out of this mess and back to both cables being disconnected....without the sparks? (or do I have to just bite the bullet and just yank off the battery cable regardless of the sparks)

 

Welcome to FTE.

You better bite the bullet and get the battery wires unhooked.

What solenoid were you talking about?
The one on the inner fender?

 

Thanks for the welcome. Yes it is the one on the inner fender on the passenger side which I have found in my repair manual as being the starter relay. Wish I would have known before relanding that red wire on the other side of the relay. Live in learn I guess. Do you know if I will cause any harm to the truck or myself with sparks when I try to yank it off? I read some stuff in the repair manual about batteries & sulfuric acid which can release hydrogen which can explode...just being cautious.

 

More damage would be caused by leaving it on. If it is still there the batteries should be completely dead by now. Just in case do not stand over the battery when disconnecting the wire.
That solenoid is a standard Ford starter solenoid used on all the older gas engine cars and trucks. It energises a larger solenoid mounted on the starter in the diesel trucks.
The many wires on one terminal are a battery power distribution point. The single wire that was on the other side goes down to the starter.

By it being on for so long I hope the starter is OK, the Mitsubishi gear reduction starter on these motors is about 430 dollars.