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I've made plenty of posts and have received excellent feedback. So, for that I thank everyone. My next issue has been the starter. When I crank the truck, everything seems fine until the truck starts - the starter gear does not disengage immediately. In other words, it's hanging up for about a second. I've replaced the starter, the solenoid, shimmed the starter, and when I had the tranny rebuilt, the transmission shop mounted the starter with the same issues.
When I rebuilt the engine, the runout on the flexplate was well within tolerance. Any help you can provide would be very much needed! Thank you.
When you release the key tumbler when it starts does it spring back to the run position immediately? At any rate if it only hangs up for a second, I would expect feed from the ignition switch. Especially with all you have already replaced.
I'm not sure what the ignition switch is doing, but I did try a starter button and got the same result. I figured that would resolve the ignition question. Thoughts?
You can try a remote start switch to eliminate issues. It's made to go between the positive battery terminal and the starter activation solenoid. Hit the button and see if the starter still hangs up. If it doesn't then your problem is under the dash. If it does then your problem is the solenoid or the starter. Kinda quick and dirty but it helps narrow things down.
Which engine/transmission do you have? Not to sound like a wise guy but is the starter centering plate in place?
The only other thing that might help is one of the new PMGR style starters with a spring loaded solenoid that should have enough force to pull out of the flywheel.