I am just finishing up a clutch job on my '99 XLT, 3.0, 4x4, manual transmission. The starter worked fine when I pulled it out, now after I've put it back in all I get is a "click". Battery is charged. The electrical connections seem to be in the right place (I don't think they'll fit backwards). I pulled it again but left the wires connected and tried starting it so it could spin freely and still just get a click. I was able to spin the flywheel with a screwdriver so it's not all jammed up in there. I can't imagine a working starter would go out simply by R&R'ing it.
Any help or advice would be greatly appreciated!

 

Welcome to the forum

There should be 2 "clicks" but very close together
There is a starter relay in the engine fuse box, its "clicks" when key is turned to START
It closes and sends 12volts to starter motors relay/solenoid and then it "clicks" and activates starter motor

On the starter motor there is the large battery positive cable hooked to the larger post on the starter relay/solenoid(small tube on top of starter motor)
Then a smaller wire hooked to the "S" post on the relay solenoid, this smaller wire comes from the Starter Relay in engine fuse box, and activates the relay/solenoid

If the relay/solenoid "clicks" but starter motor doesn't spin then its bad

Picture here: https://www.huntparts.ca/cdn/shop/pr...g?v=1679686869

The larger post is where battery positive cable goes, smaller post is the "S" post, often has a slide on connector as shown

 

Just an update: Pulled the starter back out and tested it with a set of jumper cables (neg to body, positive to large post and pos jumper wire to the small signal wire post). It looks like I somehow managed to break it. Starter doesn't move at all, gear doesn't pop out, and nothing at all when I add power to the post that goes to the starter. I've got a new one on the way. I'll update again if it somehow manages to be something other than the starter.