93, 3.9, 2wd, auto, 140K,a original except for ignition switch, water pump and radiator (and normal maintenance). I bought it new.

This has been popping up off and on for about 2 years now. Usually only in weather hot/cold extremes.

Little over 4 years ago, starter action dead. Nothing. Battery good, ran some tests, replaced ignition switch. Fixed.

About two years ago, in really cold weather, turning the key would only get a metallic snap out of starter--not the normal selenoid chatter, sounds more mechanical . Trying two or three times would usually fire it up. Sometimes taking out of park and back in would allow it to start. Or opening/closing door would shake truck enough it would start. I figured bad connection. Checked igntion switch, couldn't get it to do anything but work properly. Disconnected battery cables, minor corrosion, cleaned, reinstalled, put light coating of grease over them. Pulled only wire I could get to on bottom of starter. Lots of corrosion/rust. Cleaned everything up and reconnected. Fixed for close to a year. Problem started again, battery terminals clean, pulled same wire on starter, some corrosin again. Cleaned and reconnected, fixed for about 6 months except for blue moon occurences.

Now it's a constant problem. All connections I can get to are in good shape. Battery tests okay. Trying to wiggle ignition switch, move steering wheel back and forth produced nothing. Letting the truck roll a foot or so sometimes lets it start.

I'm still thnking a bad connection or a flat spot on the starter commutator (I think that's the part--too many years since I worked with electric motors).

Anybody have any thoughts?

Thanks.

 

It is your starter! If the solenoid is engaging but not tunning then it is the starter. Just replace it. Buy a new one or take it to a place who rebuilds them.

 

Agreed, I did the same thing for about 2 - 3 months. First turn of key the starter would just click try it 2 or 3 more times and it would turn over. In november I decided that it was time to replace it before the weather got really cold. I havnt had the problem since.

 

THanks for the quick responses, guys. That's what I thought...

Here's the rest of the story. I started pulling the starter this morning. Had to scrounge through a couple neighbors' garages to find a 6-inch extension so I could get on the upper bolt. Then either the exhaust manifold or steering shaft was in the way. By this time it was getting too #$T% hot to be working on it, so I put the bottom bolt back in, buttoned things up and started doing some research. That's what lead me here.

The only thing I could find going through the old posts was somebody saying that (on a 92 4WD) the shaft disconnects at the two ujoints, and it needs to be removed to take out the starter. I went back out and looked it over and couldn't figure out how. Anybody able to explain to me what I'm looking for and how the shaft comes apart?

I'll get up about 5am Thursday morning and tear into it so I can be done before the heat gets to be too much.

What can I say? I'm a heat weenie. I'd move north out of OK in a flash if I could convince my wife... Maybe Minnesota? I can always put more clothes on when it gets cold...

 

Pouring down rain today and no garage. Nothing done on the starter.

Can anybody give me a head's up on how to disconnect the steering shaft?

Thanks.

 

Just unbolt it and slide it out.

 

hell, ive been fighting with this problem for as long as ive owned my '93. finally the starter completely died out, just about a week ago, just before i left for camping. worst timing. from experience, just change it. i still havent cuz unlike Crazy4x4RT, its harder than it looks. i cant get to the top bolt because of the tranny cooler lines. and partially the steering shaft. however, im gunna broaden my tool collection tomorrow, so hopefully i can get the starter outta my '91 and stick it in my '93.

 

For the top bolt it is easier to us tons of extensions so you can have the ratchet by the front of the engine, that is what I did. It it makes it easier use some elbows/ flex joints. Or a flexible extension. Also I was able to turn the starter and work it out the bottom without unbolting the steering shaft.

 

I just took off the right front tire and removed the inner fender well and the starter is right in front of you with nothing blocking it! Then, when you get it loose, you just need too wiggle the starter out the bottom.

 

this is what i was gunna try tomorrow. i will try it with my '93 before i do my '91, cuz if all else fails, im stuck driving the '91 still. i was actually quite surprised that the '91 made it out and made it the week. the u-joints didnt like 140 KM/h tho lol. fun trip, just wish i coulda taken my better truck