In the electrics wiring chapter of the JTR manual there is a friendly warning phrase that says "if you only do this once, you won't do it again!" with regards to wiring the starter solenoid to the hot side of the iginition. Well, I did it while replacing the battery in my wife's van. "While I'm at it" set in and I was suspecting the starter relay was flaky so I bought a new one of those as well. There are several wires that connect to the 2 posts on the relay and I mis-placed one. Obviously it was the solenoid wire which should be on the side of the relay thats only hot while the switch is in the starting position, not while running. So with its new battery and relay the van (Ford E150 5.8L) starts fine, runs fine, but I hear this noise from somewhere around the bellhousing. Clue #1. I reason This van makes lots of noises (at 200,000 miles) so I ignore it and drive down to the gas station. While driving the AMP meter shows a discharge. Wierd. Clue #2. When I get out of the van I smell a "hot" and "electrical ozone" smell. Ready to go home, hit the key, and the starter spins, but doesn't engage the engine. Fudge. Tried hot wiring across the posts of the relay (getting very familiar with that part), no dice, tried jumping the battery. Nada. Called AAA, waited 2 hours for a tow home. Less than 5 miles, I could have walked, but while waiting I realized what I had done wrong. Too dark to try it in the parking lot anyway SO I wait until Sunday morning. I correctly wire the relay and hope for a miracle. Nope. Take out the battered starter motor, shake it and it sounds like a bag of marbles. For grins I connect it to the battery with the jumper cables still unpacked from the night before. Sure enough the motor spins AND the solenoid clicks but something is seriously shredded between the motor shaft and the gear. Teeth on the ring gear are OK, I count my blessings and carry the old motor into Advance Auto parts and buy a reman starter for $73. My Explorer still smells like toasted bakelite.