Mystifying starter problem

[homemade]

2004 explorer, auto trans, engine quits while in motion, suspect gas out.
Gas up, starter motor spins, Bendix does not engage,
remove starter, bench test OK, Bendix advances properly
12 volt at wiring on vehicle, including 12 volt switch signal
jump starter to vehicle wiring, turn switch, Bendix advances motor spins.
Try to keep Bendix from advancing with but of screwdriver, lots of thrust.
disassemble starter test clutch bearing appears fine.
ring gear fine. no bad teeth appears to be proper distance from mounting site.
can rotate engine by hand
starter cursed.
buy new starter, install, Starter motor spins but Bendix does not engage the ring gear
No grinding or scrubbing.
Homemade cursed?

 

[homemade]

Can a security module prevent a bendix from engaging?

 

[FordFool2]

I see no security related interlocks in the starting circuit. Sounds like you have proved the starter is good, it just doesn't work on the truck.

Any chance you have a 4.6L V-8? If so, you may have a damaged cable to the starter. The cable is providing enough resistance to prevent the bendix from engaging.

http://www.explorerforum.com/forums/showthread.php?t=287097

 

[homemade]

Still more mystifying. Remove starter from vehicle and jump from vehicle wiring to starter which is now lying on the ground, turn key, bendix advances, starter turns. Flex plate OK.

Ps. Thanks for replys