Reply to "Electrical Problem"

Jim,

Here's my mental check list:

1. Circuit to solenoid b/o. Not so in your case, the solenoid is pulling.

2. Solenoid b/o. Not so in your case, the solenoid is pulling.

3. Battery incapable of supplying sufficient current. I ASS U ME this is not the case here, as the battery is new.

4. Starter motor b/o. Not so in your in case, it tested good on the bench.

5. Starter relay inoperative or has high resistance contacts. Is your starter relay still in the circuit?

6. Battery cable to starter b/o or bad connections.

To check the last 2 things on my list, connect the lead of your voltmeter on the battery cable connection at the starter & have somebody turn the key to the start position. You should find at least 12.6 volts, or thereabouts. If not, the voltage is being dropped before it gets to your starter motor, by a bad connection, or burned contacts in the starter relay (if it's still in the circuit). I am again ASSUMING the connection to your starter is itself OK as you have recently un-made & remade that connection.

The new mini starters I am familiar with are built like Chevy's, they don't need an external starting relay, so the old Ford starting relay is redundant if it's still in the circuit. A quick way to bypass the starter relay is to remove one of the cable ends from the relay and then re-attach it to the same stud as the other cable. This is assuming you have a starter in which the solenoid functions as a starting relay too.

If everything else checks good, try turning the crank by hand like DeTom suggested.

Am I forgetting anything?

Your friend on & off the DTBB, George