Starter Issues
 

My friend bought a 91 Chevy S10 4x4 with a 4.3 and one of it's main issues was the starter would get hot and it wouldn't want to start. We put brand new cables and a brand new starter in it. It was hitting too hard so we added shims. He said it still died out from time to time and didn't want to start right back up. He thought it was overheating. I was never with him when it happened so I'm not sure.

It hasn't been that long since we changed the starter and cables (less than three months at the most) and it would appear the brand new starter has gone out. Someone he talked to at a shop or something told him it might have something to do with lube in the transfer case (or lack there of maybe). He wasn't very clear as to what exactly was said.

There was no cross member to remove which the Chilton's had said would need removed when we changed this starter. What is the possibility that is causing things to bind while he's trying to start it causing undue stress on the starter?

Does anyone have any suggestions as to what else to check next that would cause the starter to go back out?

Two things come to my mind:
1st - mechanical problem - not releasing the starters gear.
Make sure the pull-in solenoid works correctly and especially that it releases correctly and the small gear retracts.
Have a close look at the flywheel gear to check it doesn't get stuck or is damaged and would hinder the starters gear to retract.
Make sure it is correctly positioned (shifted) against the flywheel so it correctly engages and dis-engages the gears.

2nd - electrical problem
Might be something energizing the starter when it should not.
Check voltage and current to all starter cables when NOT starting.

Normally, if something is getting hot when it should not, it could be an indication of some current flowing.
Check once with cold engine.

Make sure all connections are correctly connected.
Remove all oxidation from any connector or relay.

Thanks
 

I appreciate you taking the time to let me know what you think. I'll relay the information when he gets back from out of state.

A starter from a 96 3/4 tonne w/454 (6449N), geared, smaller, more $$, nice upgrade if he needs to replace the starter.