Hi! I'm new here so forgive me if I rattle on. 2012 Ford Expedition EL XLT 4X4. A couple of months ago we got a deer crossing the hiway. Got it fixed, it ran great for two days. On the third day gear shift was difficult to get out of park. Finally got out of park and was driving down the hi way and it went into limp mode. Cluster lights lit up like a Christmas tree. Anti theft light blinking, low oil pressure light was on them the Expie just died on the hiway. Turn the key and get a click click click. Battery is good alternator good, but after several attempts to start it a strong burning smell comes from under the hood. Get down there and the photo attached is what we see. Never seen anything like it. Bad starter? Bad writing? Any help would be appreciated. I'm really stuck as to what caused it and what to do. Thanks fellow Ford Enthusiastics

Bad starter? Bad starter wires? HELP Thank you!

Burning smell, looks like a firework went off right next to the starter! HELP Thank you!!
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Welcome to the site.

what's with all the impact scares on the stater body?

 

That's the results of the burning smell

 

When sparks fly , that is their signature.

Time for some serious maintenance on the battery cables and connections

 

I get the black arcing scars, but the shiny indents look like 'impact' finger prints. Also looks like the starter was being manually jumped shorting to the body with tool blows to the motor case.

 

I'm guessing it's been like that for the 3 years we've owned it because before now it's never given any trouble, the picture is what we saw the very first time looking at the starter. It blew it minds to because we've never seen a starter look like that ever.

 

Can you help us out some?

Did you try to rotate the engine by turning a pulley or two, will it move ? If it will move may not be seized. If it will not move, could be seized.

The pix are before starter replacement, after starter was replaced were the battery cables cleaned at both the battery and where they attach to the vehicle?

It was mentioned that there was a concern at the starter relay. Am beginning to suspect power was being applied to starter relay and starter was attempting to respond.
Don't know at this point if this was caused by repeated attempts to start the engine or if something else was applying that power.

First we need to verify the engine is free to rotate , then verify if starter can get sufficient power to do the job and this starts at the cables and connections to the engine.

Can you get some answers to these questions before going further?

 

Haven't tried rotating engine. I will definitely try that next and I'll be able to answer that question Pictures are before the starter replacement. Battery cables were cleaned at both ends. Chased the positive terminal where the wires split to see if maybe it was resting on the AC pipe (advised on another forum) that wasn't the problem either. Starter relay was also checked, to not avail. The markings on the starter could of came from several attempts at trying to start it on the hi way when it stalled. I do know several attempts to start it caused a burning smell which very well may be where the markings on the starter came from. I was pretty desperate at the stalling point as I was on hi way TX 214 with 80 mph traffic in all directions. I will definitely respond whether it rotates as soon as we do that. We thought about timing chain after we had called it a day. Thanks again for your help.

 

A lot will depend on whether or not you were able to rotate the engine manually.

That relay that sends power down to the starter most likely has damaged contacts and should be replaced..The burning smell could have come from the starter connections.

If the starter connections are now good and clean and the engine is free to rotate AND the replacement starter is good, the engine should at least crank over and attempt to start.

What does the oil dipstick smell like ? If it has managed to get excessively hot due to lack of lube , the fragrance of the engine oil will show that.
Best to take things one at a time.

Was the starter stuck in the on position and some of the marks were from attempting to get the starter to do something?