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If the engine is warm - in my experience it should need no GP to fire. Can you confirm that it's the GP cycle that it needs to light, or just additional starting time. Try a short 2-3 second crank, then wait, then crank till it starts. This is the sequence I used before my IP rebuild. If this...

Yes, TM= Tech. Manual found here: http://www.jatonkam35s.com/jatonkaCUCV-TMdownloadpage.htm My understanding is that the DB2 does not use a lift pump in some applications. Meaning that if you have a good prime to IP, and NO leaks, the Mech Pump should not decrease performance on flat ground...

Could you post pics of your exhuast from underneath and in bed? I hate to admit it, but I like it!

I ended up removing the China Gear Redux starter and replaced it with the factory piece. The details of what led to that are highlighted in the thread below. Root cause of the no start was a faulty battery cable. Because the starter was not working correctly it is possibly that this caused the...

This morning I took the batteries in and had them load tested by 2 parts stores both times both ok. I pulled the inspection plate on the transmission and could see that the starter bendix was not returning. Having had my fill with the China gear redux I replaced it with the factory piece...

An update for what appears to be slight progress. I confirmed that I am getting the same drop at the Diamond terminal under the hood that I see at the fuse panel in the cab when the key is in the on/run position. Knowing that the glow plug system is also engaged for starting I wanted to...

Mistaken1 and Warthog: Thanks for the update - I really appriciate your time on this problem. I managed to get a few measurements taken before it got dark tonight, but can see that thinking the way you did in your last reply is what it will take to solve this problem. I would have probably never...

+1 on 1833's comment. Mine are the same way.

Yes, very good diagram. So the sparks I made could have only been @ 12V? Measuring this voltage at 0 now can not be what it was before hand, or I would have got no sparks.

I have now loosened the starter bolts agian. No improvement. I still have 24V at main starter feed. Solenoid does not recieve any voltage when attempting to start. Solenoid will not engage or activate starter when fed 12V or 24V directly. I am measuring the 12V on the fuse panel at the fuse...

I have confirmed that I have 12V on both sides of the diamond lug for the engine harness. I did not expect to see 12V here. I also have 24V at the adjacent glowplug relay. So into the cab. At the fuse panel I have 12V. HOWEVER, when the ignition switch is turned on (not start) the voltage drops...

Starter Relay swapped, no change shes still dead.

I am going to check the starter relay tomorrow under the dash. I have a back up that I will swap. Great advice mistaken1, I'm guessing I wont fail to practice this in the future! The terminal that contacted the firewall was positive. (+)

The truck has been starting and running great since the problem in this thread was resolved: http://www.steelsoldiers.com/cucv/72149-sudden-no-start-tm-says-replace-starter.html Today I slightly re routed the starter solenoid wire to gain more clearance to the exhaust. I then jumped it to the...

Edpdx, most welcome. Should any more develope I will update the forum. I plan on diving back in there one more time to repair a rough looking section of the solenoid trigger wire. It is electrically intact with some heat damage to the insulation from the exhaust. I will also re-verify the...

An update on this issue. Today I checked for voltage at solenoid and main power cable. Both showed voltage and I could hear the solenoid engage. I loosend the main starter bolts slightly and heard the starter gear snap back into home position. The starter support bracket was still torqued. I...

I replaced the starter with a gear reduction unit about two months ago. Yes, it was made in China, and Ebay. - not to jump on this as the root cause immediately. The factory direct drive unit was still working when replaced and may soon be seeing more action. Prior to today the redux starter...

Mine will run 70 actual, 60 indicated with the 37"s. I generally run about 65 actual for long interstate trips with the 4.56s.

I ended up having mine rebuild for $ 280

I completed this a few weeks back. I have several pics in my picture album that may help.