You might want to get the battery load tested to verify the battery isn't causing the issue by low voltage.  I understand that can sometimes behave this way.  Also, since the solenoid grounds to the body maybe remove it and check for a good ground connection since this might also be the cause.  Otherwise, I would only imagine a new solenoid might be needed.

Thanks guys.
I think its the solenoid. These aftermarket ones seem to be junk.
I do like Sal's idea as my starter is quite noisy, but budget wise... I may be stuck with replacing another solenoid. Does anyone make a decent one?

Toploader wrote:

Thanks guys.
I think its the solenoid. These aftermarket ones seem to be junk.
I do like Sal's idea as my starter is quite noisy, but budget wise... I may be stuck with replacing another solenoid. Does anyone make a decent one?

Standard Products is a good choice if Motorcraft isn't available.

Last edited by josh-kebob (10/31/2021 2:25 PM)

I chased that exact problem for many months. Turned out to be a bad battery cable from the solenoid to the starter, even though the cable from the outside looked pristine.

Bearing Bob wrote:

I chased that exact problem for many months. Turned out to be a bad battery cable from the solenoid to the starter, even though the cable from the outside looked pristine.

This is interesting... I may need to check this also. How long are these?

Toploader wrote:

Bearing Bob wrote:

I chased that exact problem for many months. Turned out to be a bad battery cable from the solenoid to the starter, even though the cable from the outside looked pristine.

This is interesting... I may need to check this also. How long are these?

Test resistance through the cables.  If its sky high they are bad.  Sometimes they corrode internally where it can't be seen.  Usually after 15 years plus or minus they could stand being replaced. 
 

Last edited by TKOPerformance (11/01/2021 3:13 PM)

I'm getting a new starter solenoid relay and wanted to confirm that Motorcraft is the best. I don't mind paying more for quality.
I have tried finding some NOS, but they are crazy money, if you can find them.
I suspect the one on the car might be from our favourite Country and is of a sub-par standard...

Last edited by Toploader (11/17/2021 1:08 AM)

Lots of fake Motorcraft solenoids out there made in China.

Cheap recycled copper contacts are the problem, they have the tendency to stick or corrode. In industry, silver is the standard for solenoid contact material.
I guess that solid state relays would be a better option. I have used them on some of my projects and so far have seemed to be very reliable.

Toploader wrote:

Rudi wrote:

Cheap recycled copper contacts are the problem, they have the tendency to stick or corrode. In industry, silver is the standard for solenoid contact material.
I guess that solid state relays would be a better option. I have used them on some of my projects and so far have seemed to be very reliable.

I am tired of the China crap that is everywhere on the market. I have also heard that Motorcraft are now Chinese too. Is there anything that is good quality anymore and preferably US made?
With the solid state type, I have wondered about these. Do you have any links to some worth looking at?

 

 
I have not seen any SSR’s that could replace the starter solenoid.
To eliminate the solenoid altogether get a newer style starter.

Excessive recycling is also an issue as noted.  I just bought a new set of batteries for my F250.  The minute it got cold the truck started having a hard time cranking over in the morning.  I got to thinking and it occurred to me that the batteries were maybe a year old.  Now, Diesels eat batteries, especially my generation of Fords, because at start up you are running glow plugs and cranking over an engine that's 22:1 compression.  They have a 90 amp alternator designed for the Fussion.  Instead of offering a better alternator on plow and ambulance prep trucks Ford just used two of those alternators.  I got two years out of my stock batteries, so I bought Interstate Megatrons, which lasted for 5 years.  Then kept going with the Interstates.  Two sets of Interstates later and at year 12 of truck ownership I got a set that only lasted 2 years, then the next set only one.  Then Interstate started giving me guff about the warranty saying, "Only one battery tested bad, so we only warranty that one." to which I respond "Batteries get replaced in pairs, they must be matched or the weaker one kills the stronger one.  I can have you talk to my father-in-law who did batteries in nuclear subs for 6 years in the Navy if you'd like a better explanation as to why."  All I got was a discount.  I talked to a company that specializes in Ford electronics (ficmrepair.com).  He said that Interstate bought another company and has been using recycled lead in their batteries and that's why they no longer last.  Sick of the ride I bought a pair of AGM batteries and a 170amp alternator.  Close to $800 in that setup, but I need that truck to be reliable and can't do the battery warranty dance any more.  I'm confident I'll get at least 5 years from my current setup, at which point $400 for batteries every 5 years beats $150 for batteries every year. 

On the solenoids, Motorcraft sources parts from a wide range of rebuilders/manufacturers, BUT they do have standards that must be met, so my confidence remains higher in Motorcraft than other brands.  I've yet to have a Motorcraft part die an early death.  I'd buy through Rock Auto to avoid typical internet Chinese fraud/scam parts. 
 

I’m thinking that gear reduction starters and better charging systems can make batteries last longer too.

Betcha it doesn’t have a carb.

Last edited by Nos681 (11/18/2021 11:51 AM)