I've already changed the starter relay. The wiring is all good. The solenoid gets power.

But it won't turn over unless you use a screwdriver from + to the solenoid. When I did that, the screwdriver melted really bad.

Is it possible the solenoid has a short in one spot, but it rarely stops on that part?

I noticed also whenever it would be "dead" the relay clicks really loud... as if whatever it's supplying is shorted. I think the relay doesn't have enough juice to get the solenoid off of the shorted spot. But the screwdriver has enough juice to get it kicked off.

So.. do I have a shorted starter solenoid? It's only ~3 years old.

 

I'm thinking now the solenoid is "sticky" in one spot. I've always noticed that it makes a huge clunk whenever it engages. Even brand new (4 years old or so).

 

when the starter engages a contact disc in the solenoid connects the 2 larger posts on the solenoid, sounds like its getting arced & burned a bit.

kenworth usually has pretty good pricing in genuine delco starters....

 

Not interested in delco starters, this one only lasted 3-4 years. I'll be looking at denso.

 

Well I'm going to try out a delco 39mt... they're supposed to have much better solenoids then the 42mt's. Gear reduction as well.