Starter Woes Again !

[Grenvilleter]

Ok...looking for some quick things to try. A couple weeks ago, I had immediate starter failure where everything worked except the starter armature was not engaging. So I towed the truck home and settled in to pull the starter and replace the contacts in it.
After a steep learning curve and lots of help from past posts on this forum, I pulled the starter and replaced both contacts, re-installed and everything is golden.

Last night, the wife went to the neighbors and when she was about to leave, she claims the truck will not start and got a ride home.

Now...I'm on my way over to see what is happening and at least provide a better diagnosis than " It wouldn't start. not even try slowly".

Anyhow, I'm thinking,
loose battery connection or starter power connection?
Actual movement of the contacts within starter itself ? (grumble, grumble)

Or...another possibility...

As the starter failed with no warning the first time and repeated attempts would not get the starter motor to ever run, most failures give a warning by engaging after a few trys.
While the starter contacts were worn with the battery side the most worn, I don't know what's allowed for wear?
Could this "new" failure be the old failure (dead spot on armature) again showing itself ?

Are there any grounds (neg) that may need addressing that I may be able to investigate before I tow it home ?

Anyhow ..thanks for your replies. Sorry for the long winded post.

 

[JWaldz]

Maybe loose connection that after re-install worked itself loose or the damn thing has just all together given up?? I know you hate to take it out again, but looks like you might have to. I'd check the plunger and every piece on it. These things don't last forever (like some people claim). I'm replacing mine this weekend. Ever started a vehicle with an exhaust manifold leak? That's what it sounds like when I start mine lol.

 

[JSwain]

First thing is turn the key and see what happens, if nothing then do you have a multimeter\ know how to use it?? If you do then check the battery voltage with the ignition off, 13-12.8 is great, 12.4ish I believe is about 50 percent...not great but should still start(maybe she tried more then a few times to turn it over).
So obviously if the batt voltage is below that your going to need a charge, if it is fine then take the terminals off the battery, hook up your multimeter on a low setting for ohm's, hook one side to the positive end of your batt cable and the other side to the starter power cable. Good reading would jump down to 0 or very close(no resistance\cuts\corrosion on the wire). If reading is bad(more then 0-2) clean your connections and try again, if still bad replace wire.
If the reading is good clean terminal on starter, reconnect and try again. You can also check all your grounds the very same way and it will tell you if the wire is cut or clean.
If the wires all check out and your battery voltage is good, then pull the starter and go from there...this is all super easy and free diagnostics if you have a multimeter, if not get one and you'll love it forever more as you learn how to use it. Sorry if this is hard to read it wouldn't let me post on my laptop so I'm using my phone
EDIT - Also give a good visual on the fuses while you are under there, all depends on what happens when you turn the key(if it tries to turn over or not)

 

[Grenvilleter]

Maybe loose connection that after re-install worked itself loose or the damn thing has just all together given up?? I know you hate to take it out again, but looks like you might have to. I'd check the plunger and every piece on it. These things don't last forever (like some people claim). I'm replacing mine this weekend. Ever started a vehicle with an exhaust manifold leak? That's what it sounds like when I start mine lol.

LOL...sounds like you need more than contactors in your starter. I don't think I'd get into pressing bearings but maybe your contactor plunger is sticking in too long.

I just went over to the neighbours see what the symptoms are and they are the same as the first initial failure. Contactors engaging but no spinny the little motor. Looks like I'll pull the starter and check if a contactor worked a little loose. I was so careful and thought I had it tight and in the right spot so no twist would occur. The guy at the parts counter warned me to make sure the contactors were square and properly seated and I did make note of that which makes me think a dead spot on the armature but I won't know until I get it back out and inspect.
I was really hoping it was a poor battery connection only.

I'll meter it before I go to the work of pulling it out just in case there is a low voltage issue but I somehow doubt it as I only wanted to do this job once and I thought I was very careful when changing the contactors.

Something I didn't think about beforehand was cleaning the gnd side of the contactor where it attaches to the armature/brushes. I'll have to pay close attention to that as well.

Regardless, I'll be pulling it out.

I do have another starter I could swap over but it means crawling on my back out on the cold wet frozen ground and fighting with a bunch of seized bolts for brake line movement and I'd rather wait for warm weather before I tackle that job.