I'm hoping some fresh eyes could help.

I had my starter rebuilt and have replaced my battery and am having an impossible time resolving the issue. Here's what I've done:

- I pulled the starter and bench tested it (jumpers from negative to starter body, positive to post, 12V to ignition wire connection on solenoid); it turned
- I put it in the vehicle, connected all wiring except ignition connection, and ran jumper from positive terminal to ignition wire connection on solenoid; no response from starter.
- I pulled the starter and observed flywheel; turned manually with the fan - free rotation.
- With starter out, wired 12V to positive post, ran jumper to the other wire connection to the positive post that powers everything else, and ran jumper between the ignition wire and the ignition wire connection on the solenoid. The starter turned.
- I reinstalled the starter, wired everything; no response from starter when the key was turned.
- I wired just the cable from the battery to the starter and ran a jumper from the battery to the wire connection that powers everything else. The ignition wire attached as normal; no response from starter when the key was turned.
- I ran a jumper directly from the starter body to the negative post on the battery. no response from starter when the key was turned.

I feel like I've isolated everything and the only variable is the starter being physically installed. When the ignition is turned, there is literally nothing turning and the dashboard lights don't do the dim that would typically accompany the load of the starter.

I have checked the functionality with a voltmeter during this process. THere is juice going to the solenoid, there is power being provided from the ignition circuit, and the solenoid is activating to send roughly 12V to the starter motor. Something is happening between there and the flywheel.

Anyone out there able to think of something I'm missing? I'm at a total loss.

It will be helpful if you would tell us what car is involved.

What happens when, with the starter installed normally, you jump the heavy battery cable at the starter to the small terminal on the starter?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Sorry. 1982 240D.

@ Kerry...

Nothing.

I yanked the starter out again, and it appears that it is the starter. It bench tested fine three times out of the block; when I tried a fourth configuration, it wouldn't start. That continued. The law of averages must have been working against me with the previous bench tests.

I see you did what I asked. Run a jumper cable from the starter body to the negative post on the battery, check for 12 volts at the heavy battery cable at the starter and jump a small wire from the battery cable at the starter to the small solenoid terminal. From what I can see you haven't ruled out a combination of a bad starter ground and a bad ignition switch connection.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

my thought is also an overly resistant ground connection. I would check and/or replace the ground cable and retighten its connection to the chassis.

I yanked a starter from a parts car today to test it, and it appears the issue was the rebuilt starter. Though I had bench tested it on multiple occasions with success, there must be an intermittent issue. The rebuilders assured me it was fine - they are not going to be happy to see me in their shop yet again...

Thanks for your suggestions.