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if wires are melting you have a high amp draw and most likely a dead short somewhere. I hae also heard of bad grounds causing wires to melt, but have never seen it myself.
Did you bench test the starter? take it off, clamp it in a vice, ground the frame of the starter and touch the positive term use a set of jumper cables to see if it turns over?
The click could be a bad solenoid, you can check that by jumping accrossed it (mine is mounted to the passenger side fender well inside the hood) to take it out of the loop, again, you just want to touch the starter side with power, don't clamp on to it.
does the motor turn over at all? is it locked up? bad grounds will really reak havic on an electrical system. turn the motor over by hand with a ratchet on the big bolt inside the damper. if the motor turns over, start cleaning grounds. start with the main battery to ground. replace this cable, it's 25 years old, and probly corroded inside. remove rest of grounds, clean them and put back on with a little dielectric grease to keep them from corrodeing again. clean your + battery post and cable, both ends. make sure the cable to the starter is clean and tight.
Ok well Iam gonna get the truck pulled to my house so I can start on it. Thanks for all your help, any more advice would be much helped. I will try to post my status on the truck. But no the motor does not start. The seliniod clicks and then it smokes. I will replace all the wires first then thry the other things. I dont really know what to do with the starter. So if someone could re-explain on what to do would be great.
Well the first day this happened when i was starting the truck the starter wouldnt stop. It just keept turing when ever i put the clutch in. I had to just keep the key turnt till the motor kicked. That was the last ride she gave. Any suggestions
did you ever try to turn this motor over by hand? it sounds like it's locked up. hard for me to tell, not being there. turn it over,with a socket on the big bolt inside the damper. let us know what you find
make sure your ground from the body to engine block is good and clean.i have a # 8 wire.sounds like you have a lot of resistance and that causes heat.as mentioned earlier your starter relay could be bad as well.i would replace it with a motorcraft one and make shure all your conections are clean and rust/corrosion free.my 81 did this last week and it was the relay.i replaced it and all is well.
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