Need Help!

[roundy1775]

I have a 1992 Explorer, and after a bad snow storm it didnt start. we thought it was the battery seeing as it was seven years old, so we replaced that and i didnt do anything. so we turned to the starter. we pulled it and had it tested and there was all kinds of stuff wrong with it so we got a new one and installed it. it started up but now the starter grinds when the key is in rest position. not when it starts or when it is held between start and run, just when it is in run, like it is trying to reengage the starter.
because it was fine in between run and start we thought it was the ignition switch so we replaced that, but no change. so we replaced the key cylinder. still no change.
we have also tried shimming the starter with no effect. as well as replacing the starter relay with the same outcome.
basically a whole new ignition system except the internal wiring... have no idea what to do next... any ideas?

 

[larrydd999]

Apparently the starter solenoid (not the starter relay) is not dropping out when the engine starts and the key goes back to the run position. That would keep the starter motor running. Either the solenoid is mechanically jammed or somehow it's still getting DC to the coil. Not fun, but pulling the wire (safely) from the starter coil after the engine starts would be my next test.
Is it possible you purchased a starter for a manual transmission and you have an automatic - or the opposite? I don't know the difference but understand that they are not the same.

 

[FR-425]

Yep wrong starter.

 

[xlt1993]

Had this exact same thing happen to me with my f250. The difference between the the starters for an automatic and manual are only one number difference in the parts numbers. Make sure you check your flywheel for damage. The continuing running of the starter can damage the teeth on the flywheel. Been there done that. Not fun pulling a 200 pound solid cast iron tranny out of an old truck.