Replaced starter with a new one, but truck still doesn't roll over. Battery is fully charged, voltage is flowing well to connecting wires, starter is able to be manually activated with jumper cables to a running car. There still is no power to the starter solenoid from the ignition switch. Any ideas?
The spring on the starter motor helix is either stuck or broke, or the starter gear is jammed in the flywheel gear.
Take the cover off the starter motor and you can see the flywheel, starter gear, spring and helix shaft.
If its just stuck, free it up and spray some WD40 in there.
If the gear was jammed into the flywheel teeth then check for damage
and wear. They are made from quite a soft metal and burrs can easily be
filed and removed.
The "clunk" you are hearing is probably the starter solinoid. If you
think its a more mechanical sound than that, it could be the starter
taking up slack against a jammed gear.
If the engine runs file on a pull start, its unlikely to be a jammed
gear/flywheel and more likely the spring is broke or the gear is stuck
at the base of the helix.
If its none of those things and the clunk is the solinoid, then you
will have to check to see if 12v is getting to the starter motor. If
so, it might actually be the motor.
So, in order of likelyhood/checking:
1) spring stuck or broke
2) Gear jammed on helix
3) solonoid <-> motor electrics
4) gear jammed on flywheel
Its a good idea to keep in working - very sensible.
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