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Ford: Starter and Solenoid Problem, high pitch, night answer


Question
QUESTION: I have replaced starter and solenoid with new ones, as I done previously and still the starter does not disengage once initialized. It sounds like a high winding sound.  Also previous to all this the lights came on in the middle of the night.
ANSWER: Joe, what is the year, make and model?  Why did your replace the starter?

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QUESTION: Year 2002 Truck, Model F-150, King Ranch.
This all happen when we had ICY Snow Day, drove most day and night no problem. Two days later Freezing cold when to start the truck, I only heard a "Click".  Changed the Solenoid 1st  with new one; No Click No nothing. Following day changed out the Starter; It started with a High pitch winding sound.  Replaced the Solenoid with a New one; No Nothing.  Next replace  Starter with New one and Solenoid again.  Maybe bad new parts....Same thing truck started with an high pitch winding sound.  This time I checked all harness cable in engine compartment.  Pushed all fuses and relays into place just case something was lose.  Next I went to started again when I notice that truck would not go into Automatic 1st gear; only 2nd gear position.  Moved it back to Park then went back to 1st gear position and back to park it started.  But same winding noise. Thinking maybe ignition switch or neutral switch.
ANSWER: Joe, from your description, I am assuming that the truck will start, it just makes a horrible noise during the starting.  This is typical of a starter that needs to be "shimmed."  Normally, a new vehicle does not require shimming, but you might have a unique situation.  I would suggest adding an even amount of washers to the starter to move it away from the housing (basically you will move the starter away from the flywheel so that the bendix does not get locked up in the flywheel)  If I have misunderstood your question, please let me know.   Jason

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QUESTION: Yes, I also believe in certain situation this very true.  However, had to take it the shop cause  was running out of time...and it cost me a full days work in pay.  What the shop did was take the two large cables coming off the Fender solenoid that came off each of the large post and put them to together on just one large post of the new Solenoid.  Result the vehicle starts with "No Noise".  But after one hour of use, the vehicle the engine started too run rough idle.  It seems like a plug, or plug wire loose, etc. Can this be the original problem?  Or can this just be a fluke, to a new problem.  My wife said, "That there was some gray smoke coming out of the rear exhaust pipe."  This is the first time it has happen, no gray previously.  I did floored it to see if it would clear up....Nope. What NOW?

Answer
Joe, first I have to say that I don't like the idea of bypassing the solenoid.  If the shop was able to do that and make the starter work properly, then they could have fixed it the right way.  They have basically removed a switch that could save your starter from burning up.  For example, then next time your starter tries to draw more power, then it will get more power and burn up.  Whereas, if the switch was there, it would have burned up the switch.  Now, as far as the grey smoke and rough idle, I would say that sounds like an emissions problem.  Do you have a check engine light coming on?  If you do, then this is a great way to figure out what is going on with the truck.  You can stop by AutoZone and they will check the light for free.  If a plug was loose, then you would have a "missfire."  And no, I highly doubt this has anything to do with the starter.  What I would do is "powerbrake" the truck and try to make the check engine light come on.  Or, I would take the truck back to the shop and tell them to fix what they broke.  I wish I had a better answer for you.  Good luck,   Jason