i am back asking for help. working on my brothers 96 12v. the first issue was that it wouldn't always crank over when turning the key to start position. did my search here and seems i need to install new copper terminals in the solinoid and while there also brushes. while trouble shooting it i cleaned up the battery terminals and they were fine. after restarting it i get a squeel from the front of the motor every thing looks straight in line and i changed all the items the belt touches except the alt. and it turns nice when i removed the belt. not that it couldn't be bad new parts but looking for advice. also while cycling the starter a puff of smoke came out of the fuel shut off solinoid and it needs replaced found one local for 200 bucks . thinking of changing relay also. lastly the front brakes are warped (dually one ton 4x4) from over use. when i replaced the front grease seals i removed the rotors with the hub/ bearing intact and never took it apart anyfurther to turn the rotors do you just drive the studs out to seperate it from the hub? thanks you guys dealer wanted close to 600 bucks for the fuel shut off after a couple minutes here my heart started to beat again. you guys are extremely helpful. and saved me and him some big headaches.

 

You probably hit the nail on the head with the copper terminals... does it click when you try to start it, or nothing? About the squeal... loosen the belt, and spin all the pulleys by hand, listen and 'feel' for a bad or dry bearing. Check the battery and solenoid voltage while cranking, low voltage will cause the solenoid to draw more current and overheat, or else it could be a bad connection inside the solenoid. The solenoid has 2 coils inside... one to pull in (in start position) the other to hold in (in run position). Pull in should turn off when running...could be a stuck closed pull in relay. If I remember right, the rotor should come off fairly easily... shouldn't have to remove studs.

 

Rotor is a pain, I believe I was able to smack them out with a hammer, but had to use a press to put them back in (I had one handy, but tried taping with a hammer/pulling with a lug nut first). If the discs are within service limits, you may want to have them turned while on the truck.

 

I'll bet your squeeling is the belt tensioner. they wear out pretty fast.

About the starter, you tear into it, change the contacts etc. I found myself better off over at napa for $135 you get a rebuilt starter with a 3 year warranty.

This way you just unbolt and bolt back in. If anything goes wrong with it for 3 years just unbolt and bolt back in. Depends on what your time is worth.

 

the starter will click and then nothing then retry and off it goes. just put a new belt tensioner aand belt along with all the other things the belt touches except the alt. doesn't mean one of those new parts cant be bad.

 

just wanted to let you guys know carquest starter (just because i wasn't there he is a three hour drive away) changed the run solenoid on the injection pump and the related relay and it fired right up. he said he could hear a faint squeel and it went away when he turned on a/c. still need to tackle front brakes should come apart after all being done six months ago. thank you guys again to find out the issues of a problem and what to do about them in fifteen minutes is cool.