I have a 1994 Ranger XLT extended cab 4x4 with the 4.0 engine. This morning I started it to go into town it started okay but when I went to turn it off the starter kept turning the engine over. I disconnected the ground wire at the battery to turn it off I then tried to restart it and all it would do is make a clicking sound. I installed a new starter and when I tried to start the truck it would just click again and then the small wire to the stater started to smoke and the insulation melt. Has anyone else have had this problem, my next move is to replace the starter relay or solenoid I have heard it called both ways, and replace the wire that started to melt. I hope this will solve the problem, I know just enough to get myself into trouble.

 

Yes, it reads like the starter relay on the inner fender shorted internally

It has always been a starter relay but got the Solenoid name back BEFORE Relays were commonly used and it just stuck, i.e. back in the 1930-1940's when electric starters were starting to be more common, 1949 Chrysler was the first key operated starter system, just FYI

So either is correct, Relay is just correct description of what it does, a relay makes an electrical connection, a solenoid MOVES something
Solenoids are used to open and close valves, quite a few of these in a car or transmission

There is even a solenoid/relay combo unit on the starter motor, the smaller tube on the starter, it MOVES the starter gear out, and pulls it back in, it also connects starter motor's brushes to the larger battery positive cable
So does both functions, just FYI

 

Thanks for the update I will replace the relay and install a new wire where the small wire going to the starter melted.

 

Well stupid is what stupid does, I didn't take a picture of the wire connections on the relay I know where the fuseable link and the small wire to the stater solenoid go but the main hot wires I can't remember which side of the relay they are attached.

 

The large, long, positive battery cable goes to the starter motor
Other positive battery cable goes to larger post on starter relay WITH all the other wires on same post, thats the 12volt power distribution Post
Other large post on starter relay will just have the 1 wire to the smaller post on the starter motor, "S" post, it activates the starter when relay activates

 

Thanks for the advice, after I posted what I did I googled a diagram of the relay found a picture and I'm glad I did the two 4 gauge wires go on the same post and the 12 gauge wire goes on the other post. I did that and my Ranger started right up.

 

Good stuff

Thanks for the update