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Borrow or buy an inductive amp gauge and see how much draw the starter has, when cold and when hot!!!! If it's a poor reman, bad case, or a import when the starter case gets hot the case can spread open, messing up the clearances inside the starter! IMO, knowing what the starter draws should be your first check..,.....

Originally Posted by Dave Severson

Borrow or buy an inductive amp gauge and see how much draw the starter has, when cold and when hot!!!! If it's a poor reman, bad case, or a import when the starter case gets hot the case can spread open, messing up the clearances inside the starter! IMO, knowing what the starter draws should be your first check..,.....

Can't disagree with Dave's suggestion, which is why Bug asked initially in post #2 if it was previously OK and this problem just started. There're lots of crappy replacement parts out there today....