10005-08 & 10045: Installation Instructions for Ford Starters
Installation Instructions for 10005-08 & 10045
IMPORTANT: Properly mounting the starter is important because this determines whether the
starter pinion will engage properly with the ring gear. When the starter is positioned
correctly, the starter pinion will engage the ring gear without binding and there will be no
chance of starter pinion and/or ring gear damage.
Mount Starter. Make sure the mounting surface of the bellhousing is smooth, flat and free of
paint buildup. Torque starter mounting bolts to engine manufacturer’s specifications, typically 32
Attach Battery Cable and Switch Wire. The switch wire should be
capable of handling 15A, typically a 14AWG wire. The battery cable must be the
proper size for the length of the cable (see chart). All connections should be
clean and tight and terminals should be soldered if possible. The ground cable
to the frame should be the same size as the starter cable. Also, a ground strap
should be installed from the frame to the motor. Install a jumper wire (14-gauge)
from the “BAT” terminal connection on the starter solenoid to the “IGN” terminal. (See Figure 1). (Optional: Run the “switch” wire
from the starter relay to the “IGN” terminal on the
starter solenoid.) Connect the positive battery
wire to the “BAT” terminal on the starter solenoid.
Operate Starter. It should operate quietly. Any loud grinding noises must be corrected. If the
starter makes a high pitched whine during cranking the pinion to ring gear engagement is too
great. If the starter makes a high pitched whine after cranking as the button or key is released, the
clearance is too small. The cables and connectors themselves should be checked for voltage drop
with a voltmeter. To check any wire or cable for voltage drop, connect one side of the voltmeter to
one end of the cable and the other side of the voltmeter to the other end. OPERATE THE
CIRCUIT and simultaneously measure the volt drop. It should be 0.5VDC or less. High voltage
drops indicate a bad connector or undersized cable. The ground circuit can be checked in the
same manner. Measure input voltage by connecting the positive probe of a voltmeter to the
“MOTOR” terminal of the solenoid and connecting the negative to the starter housing (should be
9.0V minimum while cranking).
CAUTION: Never operate a starter more than 30 seconds at a time without allowing time to
cool (at least 2 minutes). Overheating will damage the starter.
Why does the starter crank slowly? This condition can be caused by several things. The most
common cause is excessively low input voltage, which can be caused by undersized starter cables, high
resistance or defective batteries, high resistance battery disconnect switches or poor connectors. If the
input voltage to the starter is satisfactory (9 volts or higher), then a second possible cause could be an
underpowered starter. It is important that the starter have the torque characteristics to handle the load of
the engine. If the engine turns too slow, it may require a higher torque starter.
ADDITIONAL NOTES ON INSTALLATION
A note about ring gears. There is a lot of variation in the quality of the flexplates/flywheels on the
market today and in the ring gears that are installed on them. It is important for long starter life that the ring
gear be round and true. Check the ring gear in at least six places verifying that the clearance for the starter
is the same in all locations. If not, remove the ring gear and make sure the mounting surface of the
crankshaft is clean and free of paint buildup or rust. Reinstall the ring gear and properly torque the
mounting bolts. If this does not correct the problem, replace the ring gear.
Disconnect switches. The switch used for a battery disconnect is very important. All of the starter
current will go across this switch during cranking; which, depending on the starter, can be as high as 700A!
After the engine is running, all of the current from the alternator will be running across this switch.
Therefore, make sure that the switch that is being used can handle these amounts of current. Switches are
rated in intermittent amps and continuous amps. The intermittent rating should match or exceed the
amount the starter will pull, and the continuous rating should match or exceed the amount the alternator
can produce. Using a switch that is too small will result in voltage loss and possible switch failure.