shkira

I've seen on the site that people routinely have the same difficulties with starters. I think I've read them all looking for the Holy Grail. I am frustrated after 5 weeks of no CUCV and endless bills and still haven't solved the problem.

Everything worked great till bolt broke on the starter and had to replace the starter.

Since then...

Multiple fusible links, alternator rebuild, new battery, 4 rebuilt starters (2 unrelated sources), multiple starter relays (GM and Autozone). There is reference to a HD Napa relay but when I gave that number they told me the number crosses back to a blower moter not a relay.

No starter lasted more then 10 starts. Worst was 4.

Added new dedicated ground and cleaned up old grounds. Checked all wiring and no shorts, cracked insulation etc. Installed solenoid wire so no risk of it contacting main starter power cable. Also have traced wiring in the dash and in the engine compartment in the bundles and out -- no sign of anything wrong. Even changed the ignition switch and checked the wiring in the column to ensure no wire had worn through.

Typically would start a few times and then go back to the dreaded click. Last time started 10 times - key out of the ignition and it started to crank on its own till fusible link burned. After new ground, new fusible link and more tracing reconnected and fusible link burned again. I am now suspecting there is an internal short in the starter.

Is there a way to bench test a 24V starter?

Can it really be that I have gotten 3 bad starter rebuilds in a row?! The system is its original 24V and I wanted to keep it way. I am now seeing why people go to 12V conversions. Is it impossible to get a decent 24V rebuild?

I understand the common starter relay mod done but after 24 years of it working as GM designed it putting in a heavier duty relay would be compensating for another problem in the system. I could do that retrofit later but didn't have the problem till failure of the 1st starter. I want to isolate the real cause of what is creating this problem.

The vehicle was reliable till the stater failed mechanically. According to the MX records the previous replacement done 15k miles back. They neglected to put the support bracket back on! If they had I'd not have this problem now!

I'd like it reliable again. What am I missing?

Thanks for your advice in advance.