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Well, thats nice to know that rebuilds are not very dependable. Tomorrow I am going to NAPA to pick up my starter. The one I just took out would whine when you hit the key it never would engage. I tried tapping on it with a hammer just to get it started to get it back in the garage to work on it, but NO that would be to easy. Now tomorrow I will be laying in the driveway putting the starter in on a cold and windy day. :/
Had that same problem-with a new battery! I replaced the battery cables with some old 0 guage T33 aircraft stuff, and starter cable, make sure the grounds are clean. I also overkilled and ran a cable from the back of the starter to the frame(ground of course). Old factory cables get internal corrosion which causes resistance also.
It helped alot, since then I also changed the starter-it was weak. Beware of rebuilds, I have had them fail too-they are just old starters cleaned up and tested. Make sure your starter is good-load test preferred.
I absolutely got tired of a warm vehicle that would not start. The ZING of not proper engagement is bad-changing a flywheel or flexplate is not easy. Usually caused by a worn starter not working fully, and probable bad connections.
Now it turns over like a hot damn, hot or cold-and ready for an engine rebuild with some compression! Between 10 or 12:1 cr.
Note! If I redo my battery cables ever again, it will be with some flexible cheap welding cable(prolly not 0 gauge-that is overkill mostly)-and I will learn to tin some home made ends on. Cheap and works great!
Regarding batter cables,i use nothing but welding cable! I made power leads recently to allow me to hook up rec hitch mounted winches on the back of a couple of my trucks......I was outta welding cable,so i did a google search for discount welding supplies and found a place that sold 2G cable for less than a $1.50/ft if you bought 50 feet or more......its definitely the cheapest route for quality battery cables,and to the original poster sorry for the Hi-jack....
Regarding batter cables,i use nothing but welding cable! I made power leads recently to allow me to hook up rec hitch mounted winches on the back of a couple of my trucks......I was outta welding cable,so i did a google search for discount welding supplies and found a place that sold 2G cable for less than a $1.50/ft if you bought 50 feet or more......its definitely the cheapest route for quality battery cables,and to the original poster sorry for the Hi-jack....
Changed out the starter with a Bosch rebuild from the local parts store. Solved the problem -- so far so good.
Not sure how much the heat had to do with it. Once I took the old starter off and compared it to the new, the problem was clear. The gear on the old starter pretty much spun freely by hand and also had a chipped tooth. It's actually a wonder that it worked at all.
The swap wasn't too bad, though. Three bolts and about 30-45 minutes. Took advantage of a cold day where the sun was shining and the wind wasn't blowing. Hoping that should be about it for a while.
I personally have never had a problem with heat from the headers and my starters. If you have a good battery, decent solenoid, big cables and a good starter, I see no reason why the starter won't turn over a mild engine on a hot 90+ day.
It's usually the engines with 10.5+ compression, advanced timing and rich idle circuits that have the most issues.