Compression Ignition Addict
Join Date: Nov 2007
Location: Palmer Alaska
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Unlike most other Fords Powerstrokes are always hot at the starter cable all the way down to the starter solenoid. So if it rubs on anything grounded you can get smoke or even fire. Another possibility is the connector at the starter end of the cable is not making good contact, and the resistance is making heat. But then something would need to be drawing power for this to be the case. Check the cable all the way up to the right battery, see that the starter end is not arcing to one of the other posts on the starter. Look for galled or burnt insulation or shorting to the trigger wire witch runs in the same loom with the cable.
My baby is a one of a kind.
1977 I bought a new 76 F150 club cab.
Sitting on a 84 F350 6.9 4X4 chassis
With all the drive train and goodies from a 95 4X4 4door PSD.
Nothing stock left on her and not a nut, bolt, hose, or wire on there that I didn't put where it is.
The Wifes Ride:
2002 Excursion Limited 7.3 PSD
Themo King/Mikuni coolant heaters on both to keep things toasty without idling.