1994 F-150 XLT V8 5.8
I installed a Remy starter from Rock Auto last spring. Recently I've been having trouble starting. Sometimes lots of cranking before she starts. Sometimes nothing at all. Last night I tried the remote start and saw sparks coming from the starter area.
Backstory: This was my first starter install. When I connected the battery, there was a surge and the starter started "whirring". I quickly disconnected the batter and loosened the electrical connection on the starter. That seemed to take care of it.
When I cleaned up, I found a washer on the floor in my work area.
Question: Is there an easy fix? Like loosening the electrical connection again? Do I need that washer? Where does it go?
OR, is this a bad starter?
Or, is this something else?

 

I suspect you got a little careless assembling the wiring. We can fix that.
Maybe a little background will help.
There should be 3 terminals on the solenoid mounted on top of the starter motor.
The large top one connects to the battery positive post,the lower heavier post connects to the starter
The small wire terminal comes from the ign sw start position to activate the solenoid which passes power to the starter motor.
What appears to be happening is,,, that small wire is managing to make contact with the top post of the solenoid thereby activating the solenoid and then the starter.
That small wire should have plenty of room away from either of the large posts on the solenoid., it is that simple.
The washer you mentioned if large , usually goes on the post that the positive cable is connected to.
As you know to correct this make sure you remove the negative cable from the battery, so you can safely make sure you did a good job. When done reinstall the negative cable back onto the battery and check the operation of the starter.
If you do all this and have any kind of problem , let us know.