Starter sticking 4.3L Vortec

[ckhd]

I can't get my starter to disengage.

2001 S10 4x4 4.3L V6. I had just replaced the 4L60e. Used the exact same flex plate as before, exact same starter as before. It worked fine for half a dozen starts while I was testing things.

It decides it's going to stick and not disengage.

Here are the things I have done:

1. Thought it was yet another bad ignition switch, so I changed the ignition switch (it already had a fairly new one, but I had a new AC Delco spare on hand)
2. Thought the starter took a crap, so I put a different (used but in good shape) starter from a junkyard in
3. Thought the starter might be binding on the flywheel, so I shimmed the "new" starter to .020"
4. Then shimmed "new" starter to .040"
5. Then shimmed "new" starter to .100"
6. I have put a test light on the small wire at the starter (the one that engages the starter). It is on when the key is in start, but goes out as soon as I let off the key, so there isn't a crossed wire keeping that wire hot.
7. I have bench tested both starters. The "old" one is a little noisy, but does not ever get stuck running. The "new" one sounds like a new one, and does not ever get stuck.

It only disengages when I disconnect a battery cable.

I've spend a whole day on it. I have to leave it with my son in California and go home to Arizona in the morning. I'm at my wit's end! Please help!

[ckhd]

Update:

We pulled the starter, put it in my '97 'burb. Did about 10 starts with absolutely no issue. Before we put it back in the S10, I took off the little metal ring that is bolted to the block and goes around the nose cone. It worked great for about 5 starts, and I thought it was working, but then it stuck again.

I put the last shim in the pack in, making it a total of .120" in shims. Still sticking.

It's late. I'm going to bed. Hopefully someone has good ideas posted when I wake up.

[ckhd]

I'm not getting any traction over on the S10 page, so hopefully someone here will know.

I can't get my starter to disengage.

2001 S10 4x4 4.3L V6. I had just replaced the 4L60e. Used the exact same flex plate as before, exact same starter as before. It worked fine for half a dozen starts while I was testing things.

It decides it's going to stick and not disengage.

Here are the things I have done:

1. Thought it was yet another bad ignition switch, so I changed the ignition switch (it already had a fairly new one, but I had a new AC Delco spare on hand)
2. Thought the starter took a crap, so I put a different (used but in good shape) starter from a junkyard in
3. Thought the starter might be binding on the flywheel, so I shimmed the "new" starter to .020"
4. Then shimmed "new" starter to .040"
5. Then shimmed "new" starter to .100"
6. I have put a test light on the small wire at the starter (the one that engages the starter). It is on when the key is in start, but goes out as soon as I let off the key, so there isn't a crossed wire keeping that wire hot.
7. I have bench tested both starters. The "old" one is a little noisy, but does not ever get stuck running. The "new" one sounds like a new one, and does not ever get stuck.
8. We pulled the starter, put it in my '97 'burb. Did about 10 starts with absolutely no issue.
9. Before we put it back in the S10, I took off the little metal ring that is bolted to the block and goes around the nose cone. It worked great for about 5 starts, and I thought it was working, but then it stuck again.
10. I put the last shim in the pack in, making it a total of .120" in shims. Still sticking.

It only disengages when I disconnect a battery cable.

I've spend a whole day on it. I have to leave it with my son in California and go home to Arizona for work tomorrow. I'm at my wit's end! Please help!

[kwmech]

When you replaced the transmission, did you disturb the flexplate or starter?

[truckster]

Hook up ONLY the battery cable. Then use a remote starter or a jumper to crank it over. Does it still stick?

And just to be sure - the battery cable is on the large post that's farthest from the starter body. The other large post has a lead that goes into the starter. The small wire from the ignition should be on the post marked "S".