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Old 08-14-2005, 05:43 PM   #1
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Question Sparks fly when I try to reconnect my battery!

Alrighty I was doing the 3G upgrade on my 1980 Bronco with a 5.8M 4sp manual with Granny 1st. I got one off of '94 Mustang and it was going great until I went to turn the ignition. The starter got stuck and it wouldnt turn over. I took out the key and the starter was still kicking, so I disconnected the negative cable. That stopped it. However When I went to reconnect the battery, all I got were sparks. What could I have done wrong to cause this and what damage could I have caused with my obvious stupidity? Please Help!! btw this is my DD.....
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Old 08-14-2005, 06:28 PM   #2
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Sounds like your solenoid might be stuck or you shorted something to ground. Hard to tell though over the web.
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Old 08-14-2005, 06:47 PM   #3
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If the solenoid is stuck, its still trying to pull power, so it's gonna spark when you try to hook it up...
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Old 08-14-2005, 07:47 PM   #4
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How do I Un-Stuck it? I think you are right
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Old 08-14-2005, 07:49 PM   #5
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Tap it with a hammer. If that doesn't work than replace it.
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Old 08-14-2005, 08:01 PM   #6
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Tap it with a hammer. If that doesn't work than replace it.
So i tap it with a hammer, then I try to reconnect it, If no sparks, Im good to go?


I know that its hard to diagnose over the web, but I guess I was just hoping that I was not the only one to have made this mistake.
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Old 08-14-2005, 08:57 PM   #7
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How bad is it sparking? If it's just a little, that's kinda normal if you have an aftermarket radio or anything else that has continuous power.

If they're worse than that, the solenoid already mentioned is likely the case.
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Old 08-14-2005, 11:57 PM   #8
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I'd say if tapping it with a hammer frees it up I would trust it just long enough to drive to NAPA and buy another one. If it stuck once it can stick again, and that can burn up your starter, or worse. Assuming that you have everything wired corrrectly, definitely replace it.
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Old 08-15-2005, 02:29 AM   #9
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Replace the solenoid and if it happens again. Then you probably have a grounding issue or short.
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Old 08-15-2005, 08:31 AM   #10
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I'd say if tapping it with a hammer frees it up I would trust it just long enough to drive to NAPA and buy another one. If it stuck once it can stick again, and that can burn up your starter, or worse. Assuming that you have everything wired corrrectly, definitely replace it.
I have to tap mine every once in a while. Been doing well for almost two years. :
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Old 08-15-2005, 10:07 AM   #11
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I should've mentioned that it was starting up great before the upgrade, The sparks are BIG i mean i little piece of the terminal of the top got burned off...
To he point that I am almost afraid of reconnecting, Not for safety, but for effing up something else. I must have connected something wrong to cause this.
It should be right now but I havent gotton a chance to go tap the starter yet because we had some serious thunderstorms last night.
I disconnected the radio, I dont even have a dome light in my truck, my rear window actually works, I know its the starter solenoid causing this, I think I'll just buy a solenoid and replace it. Shucks. I would have someone do it but I bought this truck knowing I was gonna get my hands dirty, plus I'm broke!
Anyway Off topic, Ill tap it tonight and hope that works....
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Old 08-15-2005, 03:11 PM   #12
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check you wiring you might have miss connected something and if all is good tap the solinod and you should be good to go..mike
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Old 08-15-2005, 03:15 PM   #13
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I should've mentioned that it was starting up great before the upgrade, The sparks are BIG i mean i little piece of the terminal of the top got burned off...
Sounds like your solenoid is stuck. How long was your truck sitting for?
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Old 08-15-2005, 03:20 PM   #14
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Old 08-15-2005, 04:55 PM   #15
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Same thing kind of happened to mine, replaced the solenoid with one from the Zone, jproblem went away
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Old 08-15-2005, 05:35 PM   #16
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100% correct, tapped the solenoid, Sparks went away.

Now I know I connected one of the wires incorrectly, The only one that I have an issue with on the swap to 3g is the one from the plug labeled "I" color green. The alternator is from an 94 mustang. Before I eff it up, Remembering that it is a 1980 with a 5.8m Carbed, duh, What cable should I connect it to? THere is a green cable with a red stripe on it coming from the solenoid, is that it?
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Old 08-15-2005, 06:02 PM   #17
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I appreciate All the help from you guys but before you flame me....I actually have two green/red wires in that area which one do I pick? One is much thicker than the other. but I cannot see where it runs to.

This thread seems to have run dry I started a new one here http://www.fullsizebronco.com/forum/...ad.php?t=47501
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Old 08-17-2005, 07:59 PM   #18
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She is alive! for whatever reason my Hot when in run key is Blue/Orange! She is making 13.98 volts and I can nowturn on my wipers and my headlights and close my rear window at the same time!
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Old 08-17-2005, 07:59 PM   #19
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PS thanks to all for your help!!!
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