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Spent the better part of the day Sunday installing a new exhaust system, plus replacing the starter. The exhaust replacement from the cat con on down was very due, and I was pleased that the stock replacement parts were of good quality and fit together perfectly.
The starter was a different matter. The one I replaced had been failing when the engine became hot. Just an audible click whenever I turned the key. That click could have been coming from a relay as far as I know. I could get it to work if I rolled forward or back and pop the clutch while in gear and turning the key. I don't quite know exactly how that could "free" up the starter, since it never engaged the flywheel ring to begin with. At least I don't believe it did. That opinion based on what I know about starters and what the solenoid does (pushing the starter gear forward when the key is turned to the start position).
Before I put the new (used, from a scrap car with low milage) starter in, I dismantled and cleaned as much as seemed necessary. I was surprised to see the interior brush contact points were relatively clean afnd wear free, almost like a new starter. The solenoid moved freely and I used a good bit of WD40 to loosen and clean deposits along the plunger shaft. So now what I'm getting with this "new" one installed is a 50/50 start/fail. When it fails all I get is the sound of the starter motor spinning, and sometimes accompanied by the sound of the gears almost engaging - just a high pitched grinding.
So now I'm thinking that perhaps the previous solenoid was actually good, but the starter motor was bad. I may have to once again remove the starter and swap the solenoid. This is an ugly job, as it entails removing the exhaust manifold. But since I've done it many times, at least I know the proceedure.
I also managed to better insulate the starter by using some of the hood insulation padding. I've sandwiched it in between the starter and the stock metal heat shield.
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