The starter Solenoid on my 01 600TT P/N 0645-196 used from 95 to current is sticking. It will spin the starter motor until you wack the solenoid holder bracket (or battery box). I have not pulled it out yet but can anyone tell me if you can pull them apart, file the contacts, flush them out and assemble or just buy a new one? Anyone ever used a car solenoid in its place? Just happen to have a new Ford solenoid on hand.
Very easy job to refurbish. Gently spread the 4 metal clips just enough to remove the solenoid from the bracket. Then undo the remaining nuts from the solenoid so the studs can be removed from the bakelite casting. Before you remove the nuts fully from the threaded connectors, wind the nuts to the top to protect the threads and give each a sharp tap to loosen them. Carefully pry out the solenoid and flush the actuator with carb clean that contains a silicone lube. File the four copper contacts to remove any pitting from arcing. Reassemble and test.
This works great for solenoids that stick (starter continues to run with the ignition switch off). If the solenoid does not actuate you may have an open coil, measure the resistance between the two small studs (should be about 5.5 ohms) if it is open and the copper wire wound around the solenoid is not shiny, replace the solenoid as it is likely burnt out.
The ford solenoid would work but it does not have an isolated ground for the coil like the Cat one does. Coil ground it picked up via the frame mount