My truck started fine for a while. Then she stopped, and started turning over very slow. So I went to pull the starter and noticed that the wire coming from the starter relay on the fender was melted about 6 inches up and all crusty. Also, The fat 00 (?) wire that is coming straight from the battery didnt have a terminal on and and was not connected. It was just dangling there.

So the guy before me had put a new starter in my 6.9. I'm pretty sure when he installed the new one he wired it wrong.

I am not to familiar with this old Ford starting system.

I think all of the power going to the starter was going through the relay wire. Thats just my guess on why the wire was fried.

Can anybody provide me with a little insight?

Thank you

 

IF i recall right .. the smaller wire is the trigger wire and the large wire is the "LOAD" wire ... need to get those connections all doctored up though first ..

just hook it back the way the P.O. had it and see how it starts from there.. keep us posted ...

 

I am just confused on why the big power cable has no end on it. The wire going into the relay and the 00 big wire both come from a single connector which come from the battery. The wire coming out of the relay is the burned up one.

 

can you get some pics and post them .. sorry i'm just not following ya here ... need some visual .. please

 

So #1 is the wire coming from the fender relay and connecting to the solenoid. You can see the end is cooked on it

#2 is the connector/splice that has the 00 power cable (#3) leading down to the starter and the wire (#4) going to the fender relay

#3 If you look you can see it going down. This is the 00 cable that has no end on it and is just hanging there by the starter

#4 I have traced in red. This is connected with #3 at connector/splice #2. This is the wire going to the fender relay.

I took this picture last weekend. I am not home right now so I cant get a better one. But I figured this should help at least a little bit.

 

It looks like your only starting on 1 batterie ....

 

How? the other battery is connected to the 00 cable and the relay cable in connector #2

 

Ahh .. I was having anbit of trouble followin' it in pic .. now I look closer .. gotcha

.. Still trying to figure out where # 1 goes ?? is that the one your concerned with ?

 

No. Number one was connected to the starter. That was melted so I just cut the terminal off to make it easier to remove the starter. Then I pulled it up through for the sake of the picture. But #3 is the one I am concerned with. This one has no connector on it. Which I think this is supposed to be the big power to the starter.

 

OHHH , OK yeah , Your right ... now I got the Pic of what your sayin ... and YES #3 does go to starter and YES the wire that is there is WAAY to small !!!

omw .. sorry bout that , been not sleeping real well ...