Hey guys - quick update.
Yes, it does the same thing with the remote switch -AND- with the ignition switch. I have already tested continuity from the starter switch to each of the wires on the starter (and replaced the starter switch), but i tried the remote switch just to take the wiring out of the equation.
As for your other suggestions:
1. Tested the battery at home: voltage, CCA, starting system, charging system all "green", but I still need to take the battery to a shop to get tested. I also tried another battery I have on hand (used to bench-test the starter), but it has the same behaviour.
2. Done - was already bare metal, but I cleaned it with brake cleaner.
3. Done - had some paint, so I wire brushed it off, then cleaned with brake cleaner.
4. There's already a ground wire from the negative terminal to the intake manifold, a ground strap from the engine block to the frame, and another ground strap from the frame to the body. I added a ground cable (4ga - couldn't find a 2ga) directly from the negative terminal on the battery to the starter mounting bolt. Cleaned the bolt surface on both sides.
5. Cleaned both ends of the negative cable and made sure they were tight.
6. Cleaned both ends of the positive cable and made sure they were tight.
7. Cleaned up the battery posts and clamping surfaces and ensured they were tight.
With all that.... no change in behaviour. The starter is brand-new, but I thought maybe there was something wrong with it, so I grabbed ANOTHER new starter - same make/model (WAI Global 4038N). Even with the second new starter... no change.
I was stumped before, but now I'm really stumped. I'll get the battery tested at a shop, but other than that I don't know what else to try. If you have any more suggestions, I'm open to ideas. Thanks!
Quote:
Originally Posted by AZKen
Definitely an electrical problem. Please tell me that it also does that with the dash mounted starter switch and not just the remote switch. Paranoia says bad remote switch. If it does it with both, it's a sticky solenoid/bad solenoid. Wiring/cabling/ground thing.
NEXT is something you REALLY REALLY have to be thorough with so we can move on without missing it.
1. Triple check your battery at a reliable shop. The starter draws +/- 400 amps. Battery will show good charge but break down under load. Never trust a battery.
2. NO PAINT OR GREASE on starter mounting surface.
3. NO PAINT OR GREASE on bell housing mating surface.
4. Battery ground goes on starter mounting bolt. Clean bolt surfaces there.
5. Both ends of battery ground cable and it's clamps/ring terminal, tight, shinny clean, new good condition. CABLE: 2 ga min.
6. Both ends of battery positive cable and it's clamps/ring terminal, tight, shinny clean, new good condition. CABLE: 2 ga Min.
7. Battery posts, clean shinny, tight clamps.
8. Need ground straps from motor to frame, frame to body, NO PAINT.
You must not assume all is good, something is not good. So give these things we speak of a real test, not just a look.
If all that checks out, I say solenoid...or slap one on now. Maybe even a bad starter. We await your success. We will stay with you if you keep us updated.
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