I have replaced everything in the charging / starting system except the starter (rounded top bolt). When I put in the new battery, it started but it was cranking hard and kind of grinding. It started and ran like a champ but as soon as I shut it down it wouldn't start again. It seems like the solenoid is trying to turn the starter but the starter doesn't want to move. Has anyone else had this problem? Is it the starter or could it be a short somewhere?

 

sounds like the starter to me, they normally aren't too expensive, plus you've already replaced everything else, I'd do it for peace of mind if nothing else.

 

Thanks. I guess I'd better get drilling and tapping. Unless there is another trick to removing a rounded top bolt.

 

craftsman makes a set of special sockets to remove rounded/stripped bolts, not sure the price though, my brother got the set for me

 

I got a set and they only assured that the bolt was totally round. It just shaved off any points that were left. They make bolt extractor bits but I don't have enough room to drill perfectly straight into the bold. I was thinking about just air chiseling the bolt head off and getting the starter out of the way then work on the bolt shank. It might be worth the $ to have a mechanic do it as much as I hate to have some one else fix my truck. It makes me feel kind of wimpy.

 

Took a long time and a lot of work but it was the starter. Cut it off, drilled and tapped the upper bolt hole, put new starter on and now it runs like new. Also replaced battery, alternator, and solenoid.