Now What!? Car Starter Problems On 67 Ford Galaxie 500 

23 yr exp. electrician here.Since "bench" test shows good,if + is good and tight,it's usually block ground or where starter bolts up is nasty and not making ground.Two mounting ears indicates a starter for a manual transmission.Unless the other broke off,but will still bolt up.5 ribs on the nosecone tells me it is a high torque starter as opposed to a 2 rib nosecone for a 6 cylinder.Cables getting hot tells me some electrical connection is not good.Clean off the block ground wire,and where the starter bolts to trans.Sparks at battery tells me you have loose connections at battery.

Sorry bout the problems man, car looks really good though!!

Thanks for the kind words. That's most likely a rebuilt factory starter with Wilson being the Canadian company that rebuilt them at the time www.wilsonautoelectric.com/Starters , they're still in business and can probably point you to where to buy one of their re-manufactured starters if you wanted to go that route. Any starter you would get from them would probably outlast any new starter you would get from an auto parts store...however, the one you would get from the auto parts store could possibly even be less expensive than the rebuilt one and would most likely last as long as you would own the car. I noticed there was an excessive amount of sparking when touching the cable to the starter to get it to start, that shouldn't be the case. That tells me that the starter is shorting out somewhere inside and once the solenoid is activated and pushes the starter gear out the short is broken and the starter works as it should. For the money versus the trouble it would be taking the starter apart and possible finding it irreparable, I would buy a reman from a parts store like Canadian Tire, Parts source or if you wanna save some money and can wait a week or so Rock Auto would cost about $50-75. Depending on if there's one close enough to you, you might even try an auto wrecker. The 302 was used in a lot of vehicles through the years and the D2AF-11131-CA was used in most of them, so it certainly wouldn't be too hard to find. I hope that was of some help to you. One good thing about that car and that starter is the ease of access to it. It's pretty easy to remove and install! In all honesty, I would go with a starter from an auto wrecker unless a local parts store was less than $100. Good luck with it and feel free to ask any further questions you might have. Oh! Nice car BTW!

You are true a handyman. Come to see your new video.

A weak battery will sometimes cause the solenoid to engage but not have enough juice to kick it back off and then the starter and battery will start smoking, make sure your battery is charged up

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Did you figure it out? What was the fix?

Having the same exact issues with my 1966 it stopped mid park and I had to push it by myself till 6am this morning it was a bitch...