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On the turbo models,isn't there a heat shield between the turbo and the starter or is the heat shield for the battery?
I had a starter on my 83 that would not start when hot and would just click and would have to let it cool overnight before it would start again. Battery and ground strap was good. This problem confounded me for a few months and it turned out to be partially shorted winding on the rotor that became more severe from heat. The short was due to a worn bushing causing the rotor iron core plates to pinch the winding causing a partial short to the core. I took the starter apart and rebuilt it with a good used rotor, new bushings and it's been fine since.
Other things you can try is check starter RPM (should be 140 RPM or above), starter current (should be around 300 amps). Mine was drawing 500 to 600 amps due to the partial short.
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85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked
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