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Just received and installed a rebuilt starter from Rockauto today. The rebuilt starter is a BBB rebuild. there is a tech tip notice with this starter, here are some excerpts.
ford lincoln mercury, years affected - 1990 - 2003
"there have been numerous Ford Technical Service Bulletins issued with ref to NO CRANK condition in this series of starters. The problem is due to corrosion in the ignition lead and terminal at the starter solenoid. Your newly purchased starter is supplied with a new eyelet connector with lead attached" They recommend cutting off 6" of the existing ignition wire at the starter, insert in connector, crimp and heat splice.
i am changing the starter due to many "no crank" episodes. This was the first info I have seen about corrosion in the ignition lead and terminal. I hope this solves my problem, thought I would pass this info on.
I think they give that notice because most people don't look at the cables on a newer vehicle, they expect them to be good. The the company gets a bunch of "defective" returns that they have to inspect and process to find there's nothing wrong.
People usually associate cable issues with much older vehicles.
When i removed the ignition wire from the starter, it seemed to be very brittle right at the connector, the one recommended to be cut off by 6". This is on the 2000 F150, so I am sure it has seen its share of heat, it is right below the exhaust manifold. After I cut this 6" wire off, I worked it back and forth a couple of times at the connector, and it felt as if the wire broke inside the insulation. Just info on my experience this afternoon.
In every vehicle I have owned, If I had to replace the starter I always changed the cable. I usually bought some 2/0 battery cable and soldered my own connections to ensure they were good. I then heat shrinked the connections. to keep out corrosion and other junk.
I never had another issue with corrosion after I did this.
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