Poor starting 96 N plate

[simonrmcdonald]

Help. I've trawled other posts but still stumped!
I have an N plate 1996 transit 190. Its had difficulty starting recently in the cold. Wasn't a problem before the cold. Couldn't decide if it was battery or starter at first so eventually opted for battery as if it wasn't this I could twin it. All was good for a couple of days then it started playing up again. This time the starter seemed to be clicking and sometimes a metalic clanging. Got the starter reconditioned although the guy said it seemed ok but cleaned and replaced parts and the solinoid. Refitted it started easy. Tried again and heard the clang again before starting... tried again and went well but starter carried on turning! When switched off tried again and nothing! What now??

[sideshow_bill]

Worn/damaged teeth on the flywheel ring gear?

[simonrmcdonald]

Don't think so? Just to keep you posted. charged up my old battery which has a bit more oomph. put that on and hey presto, within half a turn it started. Still a little dubious though as it doesn't explain why the starter carried on turning yesterday! I'll leave it overnight now to get cold and try first thing again. Its all getting a bit expensive... New screen on Tues MOT due and tax!!!

[GBBiker]

Have you checked and cleaned the electrical connections?

[simonrmcdonald]

Sorry but been very busy so haven't been able to keep you posted. MOT day showed and I was working so I had to get my wife to take it along. All seemed fine the day before... On MOT day she started it ok to move it forward to remove stuff from the back doors but when she restarted it, it carried on trying to start (even when the keys were out of the ignition) but it didn't have enough oomph. She tried the other battery but it gave off a big spark so she felt it was best to panic and give up. I figured it must be the starter relay ceased open. When i got home I changed the Batteries again and all was fine so I reconed on the relay getting too hot, so after a trip to the breakers, got a new one (why do Ford put them in such an awful place?).
Long story short... My transit now starts with about half to a full turn of the starter and she passed for another year (thanks to my wife taking her in again)!