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One more note, you may want a second person to operate and move the other jack around. A trans jack with a tilting top piece is great because you my have to tilt the assembly left while it comes down, due to how the transfer case sits near the fuel tank.

Yep, it’s not hard, just tedious. Get yourself a transmission jack AND regular jack. Trans jack on the pan, regular jack on the transfer case. Basic idea is: - unplug batteries so some hooligan doesn’t accidentally crank during this process - put jack under t case - remove cross bar support -...

Sigh... I think I'll have to change my flexplate to finally button up this topic. Had an event yesterday where I tried to start and heard the dreaded grinding sound. The bendix tried to engage into a spot on the flexplate that was already somewhat chewed up, couldn't grab it properly the first...

So after playing with 3 different starters, it’s definitely impossible for it to fully engage, at least on my truck. The collar on the armature doesn’t allow the bendix gear to travel the full width of the flexplate gear. I stuck my phone camera under there to take a look several times to make...

Alright progress has been made. Mac Motors will be refunding me for the faulty switch and starter it burned up. In the meantime I’ve sourced a new starter and HPG is shipping me another start switch. New starter has been installed, truck starts perfectly right now with an original switch from...

Hopefully it’s just a single one and not their entire inventory, will talk to em tomorrow. In other news, spent a few hours and cleaned/wire wheeled/greased a bunch of grounds on the truck, along with installing the supplemental ground harness.

Yep that’s the plan, I still have a kascar switch coming in that’s been on backorder. Will be testing that one too as the previous ones they sent were the same type of shiny that Camo was talking about. Either I’m really unlucky, or whoever is manufacturing these switches just can’t get it...

Indeed, going to run the same tests I just did for any “new” switches that I get. Not sure about the starter procurement situation though, will make some calls tomorrow.

Basically, the new switch I installed was still sending 13-16 volts to the solenoid positive wire even when in the off and run positions. The one I stole off my friend’s truck was sending 0 volts in the off and run position, as it should be like you stated. So essentially with the new switch...

It's the switch!!!!!! I can say with 95-99% confidence now that the switches I have been receiving are all garbage. I yanked the starter, did a battery of tests on it, and then did some testing with different switches installed onto the truck. So here's what I did. Test 1 (Starter Solenoid...

This is just sad lol

Went with the rebuilt, date tag indicated it was fresh too, done in May this year. Now I’ve got a worn down probably working starter and a cooked starter haha

Yep, yanking it soon and will see what my options are with it on Monday. At this point I’m just curious to see if it’s the starter, switch, or something else to blame heh

When I originally opened this thread, the engagement was very chattery rotation but bendix fully engaged. That’s with my original switch that never fully turned to start but worked for a while. Stealing the switch off my friend’s truck solved it, my theory was intermittent engagement to the...

Yea I’m gonna do some testing tomorrow and trace some grounds for sanity. Definitely a large recurring theme with these.

It’s possible, but those 2 switches from kascar I never actually installed in my truck, since they were either the wrong orientation or not turning properly. I’ve also got that supplemental grounding harness from kascar that I haven’t installed yet, might as well put it in at this point. This...

Hey Camo, Was actually going to give you a call on Monday, I’ve seen your box before and figured I’d get one if mine ever bit the dust. A brief history on my start switch dealings: Original switch: started the truck fine up until a few weeks ago when I started this thread. It never fully...

Ok final thought before putting it to rest for the night. I wonder if it could possibly be the start switch causing this again. My initial testing and operation with this new starter were using my friend’s switch, which is what fixed my original issue. And everything was fine with his switch...

Ok some more discoveries. I just noticed that the starter is extremely hot. I drove the truck a few hours ago before this, i take it there is a chance the bendix was engaged while driving? Does the EESS/Start Box/PCB have anything to do with starter engagement? Or is it strictly the ignition...

Argh, the saga continues… I go to start the truck tonight and I hear a horrible high rpm grinding. I go to turn the crankshaft manually with a wrench, and I realize it’s not smooth and binding. Great.. feels like the bendix sticking on the flexplate. I remove the inspection cover and what do...