so i did the 2.3 to 5.0 conversion on a 93 LX. at first this problem did'nt occur but i had the 4 cylinder starter on it that auto zone had replaced for me, surprisingly it started it thogh but wore it out pretty fast. so i went and got the correct starter, it worked great for about 5-6 weeks then started grinding the flywheel. so i replaced it again, worked fine for about 5-6 weeks the started engaging ruff and grinding the flywheel, so 7 starters later it is still doing it. However i am now using a starter from NAPA for better part and somtimes it will start it perfectly other times it hits the fly wheel and grinds and other times it wont even engage the flywheel. i've replaced solonoids as well. but starter isnt getting proper voltage acording to DVOM. only read about 7.5 volts. i also replaced the wire leading to the starter. ive got the correct fly wheel and everything ive triple checked it. today i took the starter wire and jumped it strait from the battery and no change. still just grinded the fly wheel. there are also no missing teeth on the flywheel yet. has any one else experienced an issue like this and how do you fix it. i've even tried shimming and still no change please help. email me at [email protected]
serious starter issues help!!
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No Crank checklist for 5.0 Mustangs
Revised 31-May-2009 to add cranking voltage check and stuck solenoid warnings.
Since some of the tests will bypass the safety interlocks, make sure that the car is in neutral and the parking brake is set. Becoming a pancake isn’t part of the repair process…
1.) Will the car start if it is jumped? Then clean battery terminals and check battery for low charge and dead cells. A good battery will measure 12-13 volts at full charge with the ignition switch in the Run position but without the engine running.
A voltmeter placed across the battery terminals should show a minimum of 9.5-10 volts when the ignition switch is turned to the Start position and the starter engages or tries to engage. Less than this will result in a clicking solenoid, or slow cranking (if it cranks at all) or a starter solenoid that sticks and welds to contacts together.
Most auto parts stores will check your battery for free. It does not have to be installed in the car to have it checked; you can carry it with you to the auto parts store.
The battery posts and inside of the battery post terminals should be scraped clean with a knife or cleaner brush tool.
The clamp on with 2 bolts battery terminal ends are a know problem causer. Anyplace you see green on a copper wire is corrosion. Corrosion gets in the clamped joint and works its way up the wire under the insulation. Avoid them like the plague...
If the starter solenoid welds the contacts, then the starter will attempt to run anytime there is power in the battery. The cables and solenoid will get very hot, and may even start smoking. The temporary fix for a welded starter solenoid is to disconnect the battery and smack the back of the solenoid housing a sharp blow with a hammer. This may cause the contacts to unstuck and work normally for a while.
A voltmeter is handy if you are familiar with how to use it to find bad connections. Measure the voltage drop across a connection while trying to start the car: more than .5 volts across a connection indicates a problem.
See Automotive Test Tools for help for help troubleshooting voltage drops across connections and components. .
2.) Check the battery to engine block ground down near the oil filter, and the ground behind the engine to the firewall. All grounds should be clean and shiny. Use some sandpaper to clean then up.
3.) Jump the big terminals on the starter relay next to the battery with a screwdriver - watch out for the sparks! If the engine cranks, the starter and power wiring is good. The starter relay is also known as a starter solenoid.
4.) Then pull the small push on connector (small red/blue wire) off the starter solenoid (Looks like it is stuck on a screw). Then jump between the screw and the terminal that is connected to the battery. If it cranks, the relay is good and your problem is in the rest of the circuit.
5.) Remember to check the ignition switch, neutral safety switch on auto trans and the clutch safety switch on manual trans cars. If they are good, then you have wiring problems.
Typical start circuit...
Diagram courtesy of Tmoss & Stang&2birds
6.) Pull the starter and take it to AutoZone or Pep Boys and have them test it. Starter fails test, then replace it. If you got this far, the starter is probably bad.
Starter solenoid wiring for 86-91 Mustang
Starter solenoid wiring 92-93 Mustang or earlier Mustang with upgraded high torque mini starter.
Revised 31-May-2009 to add cranking voltage check and stuck solenoid warnings.
Since some of the tests will bypass the safety interlocks, make sure that the car is in neutral and the parking brake is set. Becoming a pancake isn’t part of the repair process…
1.) Will the car start if it is jumped? Then clean battery terminals and check battery for low charge and dead cells. A good battery will measure 12-13 volts at full charge with the ignition switch in the Run position but without the engine running.
A voltmeter placed across the battery terminals should show a minimum of 9.5-10 volts when the ignition switch is turned to the Start position and the starter engages or tries to engage. Less than this will result in a clicking solenoid, or slow cranking (if it cranks at all) or a starter solenoid that sticks and welds to contacts together.
Most auto parts stores will check your battery for free. It does not have to be installed in the car to have it checked; you can carry it with you to the auto parts store.
The battery posts and inside of the battery post terminals should be scraped clean with a knife or cleaner brush tool.
The clamp on with 2 bolts battery terminal ends are a know problem causer. Anyplace you see green on a copper wire is corrosion. Corrosion gets in the clamped joint and works its way up the wire under the insulation. Avoid them like the plague...
If the starter solenoid welds the contacts, then the starter will attempt to run anytime there is power in the battery. The cables and solenoid will get very hot, and may even start smoking. The temporary fix for a welded starter solenoid is to disconnect the battery and smack the back of the solenoid housing a sharp blow with a hammer. This may cause the contacts to unstuck and work normally for a while.
A voltmeter is handy if you are familiar with how to use it to find bad connections. Measure the voltage drop across a connection while trying to start the car: more than .5 volts across a connection indicates a problem.
See Automotive Test Tools for help for help troubleshooting voltage drops across connections and components. .
2.) Check the battery to engine block ground down near the oil filter, and the ground behind the engine to the firewall. All grounds should be clean and shiny. Use some sandpaper to clean then up.
3.) Jump the big terminals on the starter relay next to the battery with a screwdriver - watch out for the sparks! If the engine cranks, the starter and power wiring is good. The starter relay is also known as a starter solenoid.
4.) Then pull the small push on connector (small red/blue wire) off the starter solenoid (Looks like it is stuck on a screw). Then jump between the screw and the terminal that is connected to the battery. If it cranks, the relay is good and your problem is in the rest of the circuit.
5.) Remember to check the ignition switch, neutral safety switch on auto trans and the clutch safety switch on manual trans cars. If they are good, then you have wiring problems.
Typical start circuit...
Diagram courtesy of Tmoss & Stang&2birds
6.) Pull the starter and take it to AutoZone or Pep Boys and have them test it. Starter fails test, then replace it. If you got this far, the starter is probably bad.
Starter solenoid wiring for 86-91 Mustang
Starter solenoid wiring 92-93 Mustang or earlier Mustang with upgraded high torque mini starter.
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