I've spent the better part of the last 8 hours under my low-rider dually. I had a starter problem. Replaced it with a NAPA rebuilt unit. It turned out to be defective. Replaced it with a new (rebuilt) unit. Working toward a diagnosis. I isolated the starter using a remote starter switch from the positive battery terminal to the Bendix solenoid. The motor will crank three or four times (won't start because ignition switch is bypassed), then it just clicks. I can turn the crank shaft by using a ratchet on the crank pulley. Then the starter will crank the engine again. I don't think I have a flywheel issue (5 speed manual transmission) because it doesn't happen in the crank position (I marked the ring gear). The problem "feels" electrical. Any thoughts?

 

bad grounds or loose connections

 

I've checked and cleaned the battery cables. I replaced one of the body to frame grounds. And I cleaned the ground on the right rear of the engine block. Any place else I should be looking?

 

there is one on the intake manifold on the passenger side

 

One step ahead of you. I cleaned that one already. The truck is at the dealership now. I had forgotten what a frustrating experience that can be, not to mention expensive. I will post what they discover.

 

The starter drive is sticking in..once you turn the crank it releases.

 

I don't think that's it. But if it is, what is the solution to that problem.

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So the dealership put in a new starter... and that didn't fix it. They have also rechecked and re-cleaned all of the battery terminals and engine grounds.

The only symptom additional I can identify is that the issue seems to be tied to the crank shaft position. When the starter won't engage the flywheel, I can turn the crank shaft and get it to start. I can either put a ratchet on the harmonic balancer or let the truck roll a little bit and then pop the clutch. Either way it has the same effect. Reposition the crankshaft and the starter will turn the motor over.

Any thoughts?

 

I apologize for repeating myself with the last post.

The dealer has had the starter in and out several times (4 I think). They have tried shimming it with minor improvements. They now want to take the transmission out to watch the starter engage the flywheel.

I've seen a couple of posts regarding starters in the 6.5TD. Someone said something about a hanger??? bracket. That if you don't use it you can break a starter bolt or worse, an engine block.

My truck doesn't have this bracket. Do you think the block might be cracked allowing the tail end of the starter to drop enough to cause interference between the starter pinion and the flywheel?

 

its possible but its not likely