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I just put a brand new 390 in my 76 F-250. Almost everything under the hood is brand new except for the alternator and power steering pump. I had some kind of electrical surge at one point and fried almost everything electrical. So it has a new ignition switch, solenoid, voltage regulator and ignition control module. When its cold it fires off with no problem and runs very strong. After getting hot it will barely crank, it needs about half hour to cool before will turn over fast enough to start. I have headers that run very close to the starter so I put a heat shield on it, makes no difference. I checked all my connections and cleaned them, still have the problem. Is there anything else I need to check before I purchase a $200+ mini starter?
Side note: What gauge wire should my terminal cables be?
Where is your timing set? too much initial timing will make for a hard start when engine's hot but yet will start fine when engine's cold, are you experiencing any starter kick back?
I have never had a problem with the starter getting too hot and not turning over. I also have the same starter from when I originally got my truck back in 93, so who knows how long it was in the truck before that.
Sounds to me like Montana stated your timing is too far advanced.
Also sounds like your battery and cables aren't up to snuff. You need the biggest battery you can afford, at least 950 CCA and the very minimum 2 gauge cables, I recommend 0 or 2/0 welding cable.
I have 11:1 compression and 18 degree BTDC initial timing with that 16+ year old starter and my truck cranks just fine.
Make sure the White wire for the ignition module is hooked up properly as well. It does make a difference.
Starter is only four days old. My hot wire is only a 6 guage, could that be the source of the problem? I know its a little small but to keep it from starting, I don't know.
The voltage drop would be fairly good on a hot engine and starter with a 6G cable.
And who is really to say the "new" starter is really any good.
I tried to be cheap when the starter in my Nissan Maxima started acting up. The reman starter I got was worse than my original one. Bit the bullet and bought a brand new one and the problem was solved, but that sure sucked having to do that twice.