91 starter / solenoid problems... flywheel grinding!!

tripp7896 · 01-07-2004, 03:58 PM

this morning i was unable to start my explorer after the major cold last night.. i eventually was able to start it by placing a screwdriver across the posts on my solenoid. i then drove it to auto zone and purchased a new solenoid, started it back up without the screwdriver fine, got home and replaced it. wasn't sure about the 2 wires that weren't connected together and which posts they went on, but one way i get no power to the starter at all, and the other (the right way i believe), it starts fine, plenty of power, but makes the flywheel grind as if i were holding the key in the ON position of the ignition.

btw, the starter and battery are less than a year old but the solenoid was the original.. and i tried putting the old solenoid that was working this morning, and it also makes the grind happen.

please help!

thanks in advance,
steve

Explorer_2196 · 01-07-2004, 06:55 PM

if the starter was a refurbished one it from the auto parts store it may have gone bad.. I had this problem. Try having someone turn the key while you lightly tap the starter with a hammer. If it doesnt make the grinding sound and starts when you tap it, its most likely the starter.

tripp7896 · 01-07-2004, 07:12 PM

i said it wasn't the starter.. i said it starts up but the flywheel grinded.. so...

anyway.. it was my wiring on the solenoid.. the wire going down to the starter has to be on a post alone.. the other 2 wires connect to the post with the battery power.

amorris · 01-04-2008, 10:08 PM

I'm having the same problem. My problem started with a bad starter cable, so I went to Auto Zone and brought a new starter cable. This is the cable that goes from the battery to the starter and starter relay. The one thing different that I notice about the cable I bought and the original one on the truck was the original cable on the relay had a large "U" shaped connector which connected both sides of the relay. This mad it hard to determine which wire went where. After replacing the cable I next found the starter had gone bad. So, I replaced the starter thinking I had solved the problem, well guess what, when I engage the starter the engine starts, but the starter grinds on the FLYWHEEL. It acts as if the starter remains engages after you release the ignition switch. I don't know if I have crossed up the wire at the relay or the starter bindix are binding against the flywheel. I have a manual 5-speed transmission and was told to make sure that I replace the start with one for a manual transmission, because a starter for an automatic transmission will not work properly. Please advice, I'm at my wits end...

tripp7896 · 01-05-2008, 09:06 PM

sounds like exactly the problem i originally posted about 4 years ago. as i said, the problem, for me, turned out to be not having the wiring hooked up correctly. what worked for me was having a single red wire (running to the starter) on the right side post of the solenoid, and the other red wire and both black wires on the left post of the solenoid. then there was the red L-shaped connector which obviously clipped onto the small post.

good luck!

**BrooklynBay** · 01-05-2008, 09:15 PM

Welcome to this forum! You could easily test the starter outside of the vehicle with the wiring coming off of the starter solenoid providing that you ground the starter.

uptipis1967 · 06-04-2009, 06:23 PM

I'm having the same issue. I just replaced the silonoid, & starter flywheel is still grinding. Feels like a little lip on the teeth of the wheel. I got a reman starter from auto zone. I'm at wits end. I might just get a new car.

924dr4x4 · 06-04-2009, 06:29 PM

did the starter come with shims??cause sometimes they need shims to give them the extra space to they dont grind

uptipis1967 · 06-04-2009, 07:27 PM

I put a shim in it 1 I have a second one. Do they sometimes take two?

Quote:

Originally Posted by 924dr4x4

did the starter come with shims??cause sometimes they need shims to give them the extra space to they dont grind

924dr4x4 · 06-06-2009, 10:28 PM

mine took 2 when i did my old one,so far my starter is all good on my current explorer

sharperdude · 07-31-2009, 12:02 AM

Had the same grinding noise when i put on my new reman- starter...and the second starter...
Put a couple washers between the starter and housing to see if the noise would stop and it did... bought the ford shim and now it's fine...

01-07-2004, 03:58 PM	#1
tripp7896 Wannabe Elite Explorer Piqua, Ohio '91 XL Join Date: Jan 2004 Posts: 7 Vehicle Specs (Original Poster)	91 starter / solenoid problems... flywheel grinding!! this morning i was unable to start my explorer after the major cold last night.. i eventually was able to start it by placing a screwdriver across the posts on my solenoid. i then drove it to auto zone and purchased a new solenoid, started it back up without the screwdriver fine, got home and replaced it. wasn't sure about the 2 wires that weren't connected together and which posts they went on, but one way i get no power to the starter at all, and the other (the right way i believe), it starts fine, plenty of power, but makes the flywheel grind as if i were holding the key in the ON position of the ignition. btw, the starter and battery are less than a year old but the solenoid was the original.. and i tried putting the old solenoid that was working this morning, and it also makes the grind happen. please help! thanks in advance, steve

01-07-2004, 06:55 PM	#2
Explorer_2196 Wannabe Elite Explorer Ann Arbor, MI 2003 Ranger FX4 Lvl II Join Date: Nov 2000 Posts: 236 Vehicle Specs	if the starter was a refurbished one it from the auto parts store it may have gone bad.. I had this problem. Try having someone turn the key while you lightly tap the starter with a hammer. If it doesnt make the grinding sound and starts when you tap it, its most likely the starter. __________________ -C. Ian Crumb Jr. 2003 Ford Ranger FX4 Level II

01-04-2008, 10:08 PM	#4
amorris Wannabe Elite Explorer Olive Branch, MS 91 Explorer Join Date: Jan 2008 Posts: 1 Vehicle Specs	Flywheel Grinding I'm having the same problem. My problem started with a bad starter cable, so I went to Auto Zone and brought a new starter cable. This is the cable that goes from the battery to the starter and starter relay. The one thing different that I notice about the cable I bought and the original one on the truck was the original cable on the relay had a large "U" shaped connector which connected both sides of the relay. This mad it hard to determine which wire went where. After replacing the cable I next found the starter had gone bad. So, I replaced the starter thinking I had solved the problem, well guess what, when I engage the starter the engine starts, but the starter grinds on the FLYWHEEL. It acts as if the starter remains engages after you release the ignition switch. I don't know if I have crossed up the wire at the relay or the starter bindix are binding against the flywheel. I have a manual 5-speed transmission and was told to make sure that I replace the start with one for a manual transmission, because a starter for an automatic transmission will not work properly. Please advice, I'm at my wits end...

01-05-2008, 09:15 PM	#6
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,807 Vehicle Specs	Welcome to this forum! You could easily test the starter outside of the vehicle with the wiring coming off of the starter solenoid providing that you ground the starter. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

06-04-2009, 06:29 PM	#8
924dr4x4 Wannabe Elite Explorer philly,pa 92 xlt 4 door 4x4 Join Date: Oct 2007 Posts: 519 Vehicle Specs	did the starter come with shims??cause sometimes they need shims to give them the extra space to they dont grind __________________ john -97 explorer limited,awd v8,stock for now -92 4 door 4x4,fully loaded leather gut,8.8 rear,dana 35 ttb -86 mustang gt,5.0,5spd,aftermarket cam,ported and polished intake,ported and polished heads,flowmaster 2 1/4" dual exhaust,headers,high flow mid pipe,8.8 posi rear 3.73 gears

01-07-2004, 07:12 PM	#3
tripp7896 Wannabe Elite Explorer Piqua, Ohio '91 XL Join Date: Jan 2004 Posts: 7 Vehicle Specs (Original Poster)	i said it wasn't the starter.. i said it starts up but the flywheel grinded.. so... anyway.. it was my wiring on the solenoid.. the wire going down to the starter has to be on a post alone.. the other 2 wires connect to the post with the battery power.

01-05-2008, 09:06 PM	#5
tripp7896 Wannabe Elite Explorer Piqua, Ohio '91 XL Join Date: Jan 2004 Posts: 7 Vehicle Specs (Original Poster)	sounds like exactly the problem i originally posted about 4 years ago. as i said, the problem, for me, turned out to be not having the wiring hooked up correctly. what worked for me was having a single red wire (running to the starter) on the right side post of the solenoid, and the other red wire and both black wires on the left post of the solenoid. then there was the red L-shaped connector which obviously clipped onto the small post. good luck!

06-04-2009, 06:23 PM	#7
uptipis1967 Wannabe Elite Explorer Greensburg Pa Explorer 91 Join Date: Aug 2008 Posts: 9 Vehicle Specs	I'm having the same issue. I just replaced the silonoid, & starter flywheel is still grinding. Feels like a little lip on the teeth of the wheel. I got a reman starter from auto zone. I'm at wits end. I might just get a new car.

06-06-2009, 10:28 PM	#10
924dr4x4 Wannabe Elite Explorer philly,pa 92 xlt 4 door 4x4 Join Date: Oct 2007 Posts: 519 Vehicle Specs	mine took 2 when i did my old one,so far my starter is all good on my current explorer __________________ john -97 explorer limited,awd v8,stock for now -92 4 door 4x4,fully loaded leather gut,8.8 rear,dana 35 ttb -86 mustang gt,5.0,5spd,aftermarket cam,ported and polished intake,ported and polished heads,flowmaster 2 1/4" dual exhaust,headers,high flow mid pipe,8.8 posi rear 3.73 gears

07-31-2009, 12:02 AM	#11
sharperdude Wannabe Elite Explorer Austin, Texas 1998 Eddie Bauer XLT Join Date: May 2009 Posts: 1 Vehicle Specs	starter grinding Had the same grinding noise when i put on my new reman- starter...and the second starter... Put a couple washers between the starter and housing to see if the noise would stop and it did... bought the ford shim and now it's fine...