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I'm about to put in my third new starter in 3 weeks.
I replaced the battery with an Optima battery and cables about 6 months ago to help fix some nagging corrosion problems. About a 2 months ago I had to replace the alternator because of the diode.
Afew weeks ago the starter went. I replaced it and it lasted a week. It took me awhile to figure out this time. My mechanic looked at it and it worked perfectly for him. Got it home and it wouldn't start. I called him back, he had me jump the solonoid, same thing, hard cranking. He told me to replace the starter again and that fixed it.
Yesterday I noticed it starting to crank hard again. By the time I got home it wouldn't crank over again.
I'm taking it back today if they'll take it. NAPA is usually pretty good. Is it possible they got a bad bunch in stock?
If you're buying rebuilt parts, It's possible you're getting bad parts. They only fix the obvious problems and throw new paint on them. Maybe it's just rumour but I've heard that buying a good Ford starter cures the problem most of the time.
It seems the problem was a bad ground. I suspected it all along but it has a way of behaving like another problem. A friend helped me figure it out by grounding it with jumper cables. It spun over good when I grounded the starter to the frame. I feel kinda stupid for not trying that first. Especially when it was in the back of my mind the whole time. Incedently the first replacement was bad, throwing me further off course.