Hi, I’ve got a 1993 Ford Aerostar XLT. Was running great until yesterday, when I turned the ignition and got nothing but a click every time the key was turned. Checked the battery (had power), bridged the relay (just got clicks but didn’t turn over)…so I concluded the starter was bad. I installed …

Since what you replaced was only the starter, and the problem begin happening at that point, most likely this is a problem with the replacement starter. I’ve had bad aftermarket starters right out of the box before. If not the part itself, next up would be a problem with the install. Suggest to…

Appears the starter pinion does not retract once the engine starts. I had a similar problem a few weeks back on my car. Replaced the starter and all was well. You can whack it with a hammer, but it’s not a solution and dangerous to be under the car while the engine runs.

Thanks for the comments! Sounds like the consensus is that it is likely a bad starter. I ordered a relay yesterday that I’ll probably hook up today to isolate the problem to the starter. If so, I’ll take the starter out and get it tested…and hopefully get a new one. I’ll keep you updated, thanks!

What could be happening is the Starter gears get stuck on the fly-wheel. But its the same fix - replace starter.

[image] MikeInNH: Starter gears get stuck on the fly-wheel That could happen if the starter was installed a little cockeyed. Not flush to the mounting spot for some reason. Doesn’t seem likely, but if you end up removing the starter good idea to check that the mounting is properly aligned at…

GeorgeSanJose: Not flush to the mounting spot for some reason. Doesn’t seem likely, but if you end up removing the starter good idea to check that the mounting is properly aligned at that time. If the starter requires shims then it’s a more likely to happen.

I replaced the Solonoid switch (the part Rod_Knox points out above) yesterday and problem persists. I removed the starter and will be taking it back to be tested and get a new one under warranty on Saturday. There were no shims when I took the original out, so I assume none are needed for the repla…

When you removed the starter did you inspect the teeth of the starter and flywheel? Look for chips or undue wear.

The Starter teeth looked good. Couldn’t get an angle to see into the flywheel, but reached my hand in and the teeth weren’t noticeably worn at least from touch

Starter keeps cranking while engine starts and even after turned off

Maintenance/Repairs

Rod-Knox June 22, 2017, 12:40pm 14

Your van seems to have 2 starter solenoids and this one

http://www.autozone.com/batteries-starting-and-charging/solenoid-switch/gold-solenoid-switch/184961_213556_0

is prone to sticking in the ON position

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Starter keeps cranking while engine starts and even after turned off

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