So, .. here's the scoop, I need to leave on a trip the middle of next week and need my truck running by then. It has stiction issues, and over the past few weeks, obviously it's been super hard to start (sometimes takes 15-20 minutes of 2-3 glowplug cycle/crank for 3 seconds, repeat) to go (can't plug in, outside parked at a job site for example);
Now it won't start. Starter grinds/just spins, so I pulled it. Checked it off jumper cables and saw the bendix was only coming out like a half inch or or less, you could even see where the teeth had been grinding on the flywheel, not full travel for sure.
So I tore the starter down completely, it was a little dirty inside brush dust, etc. but OK, no broken connections, everything was electrically solid, including contacts and solder points on the solenoid. After cleaning everything thoroughly I put it back together and tested it again, sure enough the solenoid now was engaging the bendix full throw. So I put it back on...
Does the same thing, only this time it never 'spins', always grinds. It's almost like the motor is locked up and won't turn over? I refuse to spend $311 on a new starter from the local auto parts store, and ordering one on the internet for $75 (new) is going to take longer than when I need to leave... so the question is, has anyone else seen this and is it fixable? A new solenoid online is like $45 from ebay, I could check the dealership but I assume you may as well triple that price.
Ideas are welcome...