I have a 1996 cobra with only 65000 miles on it. I've owned it about 2 years and put maybe 200 miles on it when it developed a starting problem. It sounded like the starter grinding against the flywheel. I replaced the starter with a new one not remanufactured. Same problem. I was told the flywheel probably had a bad spot in it and needed to be replaced. I did not check it and took it as it was per the forum. I turned the motor over by hand and then the car would start fine, this seemed consistent with a bad flywheel. I attempted to do it again and couldn't. I have been trying to sell the Cobra and actually posted it on the site today.
Anyway, I decided to pull the starter out and turn the motor over by hand to inspect the flywheel for any bad spots or broken teeth.... Nothing, no worn spots nothing on the flywheel. Any suggestions that might cause this? Any and all help is appreciated, I would like to get what cash I can for my car, thanks.
Jonathan email me if you want, race06@comcast.net
Last edited by race06; 4 Weeks Ago at 06:12 PM.
Reason: spelling error
Jonathan, tell me exactly what it does. If it's not the flywheel, there's only two other things it may be. Either you ended up with another bad starter, or you have a bad solonoid. Check all your connections, to make sure they're all clean and tight also check your grounds, Mike. SCT Tuner. P.S. I have a 96 SVT Cobra Convertible, with 55,187 original miles and never had any problems with the starter. Check the connection, between the battery and the solonoid and make sure it's clean. Make sure there's no corrosion around the connection, also make sure your cables are all good. I'm thinking as I go along, I would hate to see you sell it over something simple, Mike. Good Luck!!
I have the original starter/flywheel on my car, 1996 with over 150k miles, it's about the ony thing that hasn't been replaced...does it make the sound all the time, or just when you turn it over with the key?
__________________
"Goose, Hollywood's fine, I want Viper"
1995 Mustang GT Cnv 347(427 stroker being built!) almost done!
1996 Cobra with Kenne Bell 2.1 Supercharger and every other conceivable part you can bolt on it...650hp upgrade in the works
2003 Infiniti M45 V8 340 hp...a methadone treatment for reformed Mustang drivers
Jonathan, tell me exactly what it does. If it's not the flywheel, there's only two other things it may be. Either you ended up with another bad starter, or you have a bad solonoid. Check all your connections, to make sure they're all clean and tight also check your grounds, Mike. SCT Tuner. P.S. I have a 96 SVT Cobra Convertible, with 55,187 original miles and never had any problems with the starter. Check the connection, between the battery and the solonoid and make sure it's clean. Make sure there's no corrosion around the connection, also make sure your cables are all good. I'm thinking as I go along, I would hate to see you sell it over something simple, Mike. Good Luck!!
Connections looked ok, new battery as well. Nothing corroded. It only happens when I turn the key to try and start the car. I looked inside the starter and can see the gear/teeth looks like contact is/was made... I've never seen this before on new starters I have heard of this on remanufactured though. I might take the starter to Advanced Auto tomorrow to be tested and see what happens. Very puzzling.
I'm thinking it's the starter, if it was a spot on the flywheel it probably would be more intermittent...it could be that the starter is slightly misaligned or that back bolt that is so hard to reach is loose or not there.
__________________
"Goose, Hollywood's fine, I want Viper"
1995 Mustang GT Cnv 347(427 stroker being built!) almost done!
1996 Cobra with Kenne Bell 2.1 Supercharger and every other conceivable part you can bolt on it...650hp upgrade in the works
2003 Infiniti M45 V8 340 hp...a methadone treatment for reformed Mustang drivers
I'm thinking it's the starter, if it was a spot on the flywheel it probably would be more intermittent...it could be that the starter is slightly misaligned or that back bolt that is so hard to reach is loose or not there.
all the bolts were there. The top is a bi&(ch to get out. I appreciate the feedback and will let you guys know what develops when they bench test the starter. I kept the old factory one and will have them test it as well. thanks.
Well, I had Advanced Auto test the old starter and the new replacement. The old one worked although the bushings didn't sound that healthy. The new one, tested fine as well, no problems. Solenoid is fine, etc. This is completely odd.
Going back, I first diagnosed this problem as a bad starter based on experience as it started hard and the original starter just seemed tired and worn out when it finally stopped working, hence the grinding noise started. I replaced the old starter with a new, not remanufactured, it fired up fine the first time, shut it off then the same grinding noise after I tried to start it again. I was told "you probably have a bad ring gear around the flywheel."
Fast forward to now, I inspected the flywheel, don't see any problems with it, starters are tested and engage fine, new battery, no corrosion on the wires, what am I missing? Has anyone ever had a problem with their Cobra like this? thanks.
Last edited by race06; 4 Weeks Ago at 12:40 PM.
Reason: added content
I have been checking the web since my last post to see if anyone else has had a similar Grinding noise trying to start their Cobra. I found several other forums where other Mustang owners and F150 onwers had similar problems 4.6 liter and 5.0 engines, replaced the starters and flywheels and their problems persisted.
Is it possible this may be simply electrical, where a bad wire is not allowing full voltage to the solenoid? My Cobra is bone stock and I don't see a problem anywhere unless it is in the harness somewhere hidden. Any ideas on the easiest place to start if this is a possibility?
Since my last post, I reinstalled the new starter, replaced the battery terminals made sure all was clean and tried to start it.... Same grinding noise. I have begun to inspect all the wires from the battery to the starter and all look good. I checked the voltage at the battery and the starter and the voltage is the same. Any thoughts? The starter appears to turn slow and the grinding noise seems to be happening due to the fact it is not engaging the flywheel with enough power. HELP!! I am so over this.
Doing some additional research about my starting problem and read on the Web others have had problems with their Fords with similar issues also with the "theft" light flashing. I just realized today the "theft" light was constantly flashing. Is it possible that this part of the PATS system could be causing a problem?
Hi guys. It's been a week or more and I've spent quite a lot of time on my car trying to solve my starting problem. Starter tested fine at Advance Auto. I bought a scanner reader and there are no codes on the computer. I replaced the wires from the starter to the battery (there was only two; one small and one large) and I replaced the negative battery cable and put an additional ground from the motor to the chassis. I am still have issues, it is still making the grinding noise and the starter will not engage the flywheel. I know it is not the ignition as I put a remote starter on it and it still acts the same way. Any suggestions? I have no idea what else to do. The Cobra only has 65000 miles on it and ran excellent until this problem.
I forgot to mention I replaced every fuse under the hood as well, just in case and tested each one in the dash and they are good. I want to sell this to buy an older Stang but this problem is driving me crazy, thanks for the help.
I gotta tell you that this is weird, I have over 150K miles on my 96 cobra and it still has the original starter/flywheel, I may have to go out on a limb here and wonder if the car was wrecked and somehow the subbody is bent or something not allowing proper contact/alignment...have you had a Ford SVT dealer look at it? Good thing you live in a big city you should be able to get some pro help. Good luck, keep us posted.
__________________
"Goose, Hollywood's fine, I want Viper"
1995 Mustang GT Cnv 347(427 stroker being built!) almost done!
1996 Cobra with Kenne Bell 2.1 Supercharger and every other conceivable part you can bolt on it...650hp upgrade in the works
2003 Infiniti M45 V8 340 hp...a methadone treatment for reformed Mustang drivers
That is a very strange problem. . . I would suggest going to a reputable ford dealer in the area and asking to have a chat with the lead technician. Honestly, I don't know what to tell you other than that.
thanks for the feedback guys. the car has not been wrecked all original right down to the rubber bumpers and bolts that hold them on. all the years that i have worked on cars, this is odd to say the least. i did consult a ford tech and he thought the same thing, that corrosion set inside the wires to the starter, which is why I replaced them.... no result. Anyone want to by a Cobra for $6000 and deal with this or best offer?
I discovered the problem!!! I was able to turn the motor over once again by hand, I put lipstick on the starter gear to make sure it engaged the teeth on the flywheel and it did, nicely I might add. Then, I after turning the motor over, I was able to get my hand where the starter mounted and turn it a bit by hand once again, the ring gear has broken away from the flywheel!
It's not too loose and you really need to grab on it to notice it but the noise is coming from the starter turning the ring gear.
Now, I just don't know whether to fix it or sell it as is for a fair price.
1996 Mustang Cobra starting problem 
