Hi,
Just got this '91 B2200 5spd (standard) with 262k.
Running fairly well. (leaks a lot of oil)

However, once hot if I turn it off then try to restart it...it will not turn the engine over until it cools 20-30 min.
It will rotate engine a little, but as if the battery is dead. Not enough to start it.

In morning when cold starts after 6-7 "rotations".

What done so far:
new battery
new starter
had battery and alternator tested twice. Once O'reillys. Another at Auto Z. Both Said alt and batt. are fine.
I added a ground from engine case to chassis. This did NOT help.
I am planning to replace ground wires tomorrow .
(I read online that could be issues with ground wires building up resistance.?)

I plan on looking at:
Fusable links?
Starter relay?
Voltage regulator of some sort?
Ignition switch?

Thanks for any input.!

also, couldn't upload photo for some reason in the meet & greet section. Thx

 

I'd test the electrical part of the ignition switch WHEN the truck will not start. These are weak spots as these trucks get old; I replaced my own switch in my '88 back about 1995.

And don't forget to also check the safety switch on your clutch pedal.

I'd like to know the voltage reading across the battery WHILE it's trying to crank the engine.

 

Thx Cusser.
just to clarify to know what I am testing...
ignition switch: test at column near steering wheel? Checking to see that it has current? and how much?
clutch safety switch: checking to see it is getting current? or if it is heat hot? or that it functions mechanically?...or all?
thx

 

Did some tests

Across battery:
12.5(+) not running cold or hot engine
9-10v while cranking cold or hot
13 (+) while running cold or hot

Starter:
12 (+)v not running cold or hot engine
9-10v while cranking cold or hot engine

Ingnition switch at steering column:
With key on but not cranking.
( I am assuming the Blk/yllw is ground ?)

This is when hot (after run for 30 min. or so)
Blk/Ylw - Blk/wht -10v
blk/ylw - blue . 03v …..(but also had a -9v when cranking
blk/ylw - blk/rd -12v
blk/ylw - wht/red 11.75v - 12.78v

I put meter on clutch switch but got nothing. is this to be done while cranking?

 

Black/yellow goes to the clutch pedal switch, and then on to the starter. The clutch pedal switch only has continuity when pushed down, and will also only have voltage going to it when trying to start. A starter needs to have minimum of 9.6 volts to get it to operate.

Have you tried a jump start from another battery?
Cleaned all your connections and terminals?
Tried "jumping" your starter by putting in neutral and momentarily shorting the small wire connector at the starter to the large 12 volt positive wire terminal ? Be careful,
things like fan could start to spin.
Tried "jumping" your ignition switch by putting in neutral and momentarily shorting the Black/yellow ire to the hot wire?
Above tests will help diagnose your issue.

PM me with your E-mail address, and I'll send a wiring diagram manual; will be for later year but still applicable.

 

Posts and connections are clean.
Tried jumping from another running car. Just turned slow to dead.

Ignition switch is "hot wire" blk/red?

will try other suggestions tomorrow.
Thx

 

DID this today while engine hot and not turning over :

jumped at ignition switch = slow/no turn over. no start. (fyi blk/ylw to blk/rd)

jumped at starter = starter spun by itself freely (with ignition OFF)... BUT (ignition ON) when engaged w/ engine slow/no turn over

I can push start the truck pretty easily.

Perhaps I got a dud starter? from autozone?

 

Ugh... in my experience, every part i get from autozone needs to be brought back at least once for a new one.... Especially alternators. Since the return is free i'd try popping free-b starter in.

 

Hi Greenbee,
Thanks. Yes. you are exactly right.
I took the first one back and got another.
The 2cnd starter is better...…...
However, the 2cnd starter is now having problems. When cold it just spins for several cranks. sounds like it is not popping out to engage flywheel.
So, I bought a 3rd one! from Rock Auto. It is an AC Delco. haven't had time to put it in. hope to in the next couple of days.

Also, My apologies for not posting anything about my findings.
Meant to do it but got side tracked.
I really appreciate all the help.
Thanks!

 

I installed a "brand-new" Autozone starter in our 2005 Yukon about 5 years ago, and it's been fine (and lifetime warrantied). I installed a rebuilt CarQuest starter in our 1998 Frontier about a dozen years/110K miles ago, and that's been fine as well. So that's my only hands-on experiences with starter installs except for my old VWs which have Bosch starters.