click but no start

[Slednut10]

Went to start the Bronco this am and only got the dreaded click of the start solenoid. Lights work. Battery checks at 12+ on the multimeter. Jumped the solenoid to check for voltage across the terminal and its there. Battery is grounded at the block and the core support. Block is grounded to the frame and continuity checks show good everywhere I tried. Truck has a mini starter that I have not checked yet due to the need to be at work. The odd part of this is when I was checking the solenoid I saw smoke on the right side by the brake booster. Checked for evidence of a short or burn but finding none, I tried the solenoid again and saw a spark and then a flame from the rag joint on the steering shaft-yes the rag joint. Obviously this will need some troubleshooting as there appears to be more than one issue here, but I figured I would throw it out there so I'm not the only one scratching my head.

 

[ransil]

shitty ground just because they are there does not mean they are good

clarify a little, the sparking/ smoking at the rag joint is the ground trying to find a path.

 

[Ourobos]

^ I agree. Run a ground from starter bolt to frame, solved same issue for me in two of mine.

 

[Slednut10]

^ I agree. Run a ground from starter bolt to frame, solved same issue for me in two of mine.

Agreed. I was figuring since my neg cable was bolted to the block the connection couldn't get much better (wrong!)

shitty ground just because they are there does not mean they are good

clarify a little, the sparking/ smoking at the rag joint is the ground trying to find a path.

Agree with you 100% Ransil. Just figured I'd toss it out there in case there was something wierd I was overlooking. The sparking was strange to me considering the level of grounding I had just to avoid this kind of issue. Turns out it was the negative battery cable. Took me multiple attempts at cleaning, moving, verifying etc every ground in the engine compartment and only after noticing the 10 ga ground wire for the core support was hot (after cranking) did I suspect the 1 yr old battery cable. Made up a new one with a compression end that I had in the trail repair kit and some 2 ga welding cable.

 

[dave67fd]

Glad you solved easy enough Art.
Connections and cleanliness I always say.;D

 

[Brewbro21]

also tap your bolt holes for the starter to the block and wire brush the bolts to get shiney metal for a good path also. Doesnt hurt to rub some emery cloth on the mating surfaces on tyhe starter and the block to get a good connection.

Battery cables shold be able to last decades let alone one year with no issue. It's awesome all the cheap copper the U.S. has been getting from China, I see alot of non pure copper in our wire and cables at work, all from chinha too!!!

 

[Slednut10]

also tap your bolt holes for the starter to the block and wire brush the bolts to get shiney metal for a good path also. Doesnt hurt to rub some emery cloth on the mating surfaces on tyhe starter and the block to get a good connection.

Battery cables shold be able to last decades let alone one year with no issue. It's awesome all the cheap copper the U.S. has been getting from China, I see alot of non pure copper in our wire and cables at work, all from chinha too!!!

Funny you mentioned tapping the threads-did that and flap wheeled the boss. I even moved it to another threaded hole. Drove me nuts. Meters out perfect too, but put a load on it and.............. Just glad it didn't fail during MEB!

But a crappy piece of #6 vice gripped to the post and nutted to the exhaust manifold worked. I'm going to cut the battery end apart just to see what it looks like.