1994 Explorer Electrical issues

[exploder88]

Hi all.

1994 Explorer 4.0 auto 4wd. Took it to 7-11 and it ran fine. Came out of the store and go to fire it up "nothing". No lights, no click. Battery tested bad and replaced. Try to start it again and I got a single loud 'click', then multiple fast clicks. Tow it home, replace the starter (its fairly old), positive cable, solenoid, and cleaned the grounds. Also replaced the new battery with a different new battery.

So I go to start it, and it starts, but there's a horrible grinding noise, so I shut it off. I replaced the new starter, with the old one to make sure it wasnt a clearance/shim issue, and the new starter makes the same grinding noise, and theres smoke coming off of the small wire that goes to the starter solenoid. Lots of smoke.

I'm just frustrated right now, and looking for possible causes/solutions/things to double check. I have tools to do damn near anything and am fairly handy.

Thanks in advance

 

[osteologation]

Check ignition switch. I've had to replace those on every ford I've owned of that era. They do some weird stuff before they let go.