not same problem , maby the ignition switch ! your problem is easier to solve

 

christg,have you done the direct bypass yet?any change?I am about to try the same thing because of the grinding starter issue.I've replaced my flywheel and starter in the past only to have it grind again.I dropped the starter recently to see what shape the gear was in and it was still in excellent shape.After all the reading etc... i think this must be an electrical problem ,maybe a voltage drop every once in a while causing it not to engage properly.

 

Is your alternator charging your batteries at all rpms? Mine had to be serviced when my mech. friend checked my system at an oil change with new batteries and sure did catch it this way. Didn't warranty it he just fixed it and I don't have exact circuits or part it was just now. Works at max now and belt is just fine too older belts can start a problem not very often now days though.

 

I have an 05 LLY that has had the starter problem a few times. I saw somewhere it may be a computer problem. Since then I have always turned on the ingnition and wait for the heater fan motor to start. That is an indication the computer has finsihed booting and is active. That is when I will start the engine. So far it has not done the grinding operation. But I can not be sure yet as it had only done it 6 or 7 times before I started waiting for the computer. I started doing the computer wait about 9 months ago.

 

I have an 05 LLY that has had the starter problem a few times. I saw somewhere it may be a computer problem. Since then I have always turned on the ingnition and wait for the heater fan motor to start. That is an indication the computer has finsihed booting and is active. That is when I will start the engine. So far it has not done the grinding operation. But I can not be sure yet as it had only done it 6 or 7 times before I started waiting for the computer. I started doing the computer wait about 9 months ago.

My truck was doing the same thing, spent $150 on a new starter, same results. Started waiting for the computer to boot up, haven't had a problem in over a year. I have no idea why this works, but it does.

 

When I use my truck as a DD it can happen as often as once per day. At first it was about once per month, then every couple weeks, then every week, and so on.

I could believe that it is an electrical issue, I have had some in the past (bad batteries and now the new ones dont seem to be charging correctly).

The only thing I worry about now is that the flywheel is damaged and in need of replacement.

 

My 03 does it every month sometimes then every week then back to every month again so I just quit worrying about it.

 

You guys who wait for the computer to boot up, How can you tell this is happening? Im sure I wait for it because I always wait for the glow plugs to finish before I crank.....

 

I wait until the blower on my HV system starts. I have my HV system set to auto on my truck. It takes about 1 minute. I just turn on the ignition as soon as I am in the truck seat then use this time to fasten seat belt etc. I have found in the summer the glow plugs do not always come on. It was also in the summer I had most of the problems. Probably because I did not have to wait for the glow plugs to finish.

 

I do had time to investigate the problem anymore. the problem seam to be that gm use low duty starter system on a medium/heavy duty engine. heavy duty starter on heavy duty truck have a protection to prenvent starter from spinning if the gear is not fully engaged.

After all i found a trick that can help until someone found a full fix

if i only give a very small burst of start before trying to start that help !

using this method the starter gring come only 1 time for 50 crank versus 1 / 10 crank without using this method

if you give only very small start burst you can ear the noise if the gear engage corectly

give only very small burst until the gear engage corectly, then start the engine normally

using this method the starter will not grind as much as if you try to nornally start your engine.

 

I do had time to investigate the problem anymore. the problem seam to be that gm use low duty starter system on a medium/heavy duty engine. heavy duty starter on heavy duty truck have a protection to prenvent starter from spinning if the gear is not fully engaged.

After all i found a trick that can help until someone found a full fix

if i only give a very small burst of start before trying to start that help !

using this method the starter gring come only 1 time for 50 crank versus 1 / 10 crank without using this method

if you give only very small start burst you can ear the noise if the gear engage corectly

give only very small burst until the gear engage corectly, then start the engine normally

using this method the starter will not grind as much as if you try to nornally start your engine.

My dealer warned me not to short crank a Dmax. Maybe someone can chime in and expalin why this is not good practice.

 

LOL Stealer know you must not short crank but dont know how to fix problem , this is pathetic !!!!!

 

Add me to the list!!! GRRrrrrrr This is soo frustrating. Mine started about 4-5 months ago and I just dealt with it because it was only 1 in 50 starts. Now its gotten to the point that its maybe 1 in 10 starts. I just pulled my starter and had a reputable shop rebuild it. They said the "drive" definitely had something wrong with it and they replaced the clutch and solenoid as well. Guess what? not even 24 hours after installing the "rebuilt" starter my grinding is still here! The shop asked me if I checked my teeth on my flexplate and I told them I did and there was nothing wrong with any of them just a few shiny spots where the starter had grinded. I took my HD camcorder and aimed it into the starter hole and took a nice HIGH RESOLUTION video of the flexplate as I spun the engine over. Here is the link to my HD video if anyone wants to check it out and tell me if you see anything out of the ordinary. I took chalk and made marks & numbers on the flexplate so I could reference where I was so you will see some chalk lines on a few teeth but they are definitely not damaged in any way.
http://teamls1.com/flywheel.wmv

Im beginning to think its definitely an electrical issue. either a relay or computer issue. gotta love all the new computers in cars these days. I think I will try the "direct switch" idea and see what comes of it. I'll let you all know what I find.

 

Here is the diagram of how the 04 Dmax starting/charging system is laid out. I am going to do some testing and bypassing some things to see what I come up with. Starter wire comes out of the ignition switch (12v), goes through the 10amp crank fuse into the ECM, out of the ECM (ground/relay control) into the Starter Relay, then out of the Starter Relay (12v) and finally to the Starter Solenoid. As much as I dont want to, I think I am going to trace down each of the wires from the switch-to ECM-to-Relay-to-Solenoid and make sure none are corroded or bad connections and maybe even try replacing the starter relay. This is just insane that this many people are having the same problems with starter grinding and no-one can figure it out. I think GM should offer a reward to the person who figures this thing out! lol

 

So I am guessing you guys are saying the problem is in the circuit that tells the starter to go (triggers the relays), not the power that actually powers the starter?

 

Add me to the list too! I was going to do as others have done with removing the starter and rebuilding or replacing. But now I think I'll just live with it until someone solves the issue. My LBZ never misses, I wonder what changed between the years other than ECM controllers. Are the starters the same part #?

I think I will check and redo every ground point as a start.

 

I've been dealing with the starter issue for about a year and a half now. Started rare and now I'm lucky if it doesn't do it every time I start the truck.

Max it has taken has been 10 grids in a row before starting, usually one or two then cranks. Have tried 2 starters and a flywheel.

I was looking at that wiring diagram and am going to try something, I'm going to try a switch with 12v power connected to the PPL wire going to the starter so I turn the key on and push the button to start, skeptical that it will work but worth a shot.

 

since i give small start burst before starting mi pickup i never had the problem again, try it !

 

Dono, personally I don't like doing that. To be honest don't really have a reason why mechanically or electronically, just doesn't seem right.

 

The problem is that gm has put low duty starter system on a medium/heavy duty engine, heavy duty engine should have starting system with pignon position detection system. duramax use same starting systeam than every car LOL. The problem is on some engine, the clearance between the pignon gear and flywheel gear is too tight by some fraction of milimeter

What i am sure is that giving ONE small burst before starting my pickup , it far better than the pignon grinding on the flywheel ...

as far as i know mechanic, i cant tell anything that can be bad for the engine by giving one very small start burs before starting the engine

if someone can explain what is bad tell it otherwise shut up please.

If i had not found this trick my next step was to tryi to grind the starter mound hole to set it farther by 1/2 millimeter from the flywheel

 

First off how about you update your signature so we can see what kind of truck you have.

Now you say its because its a light duty starter, it seems that this is only a problem with the LLY's........so I ask again, has anyone put an LBZ starter on an LLY and will it even fit?

 

keep you informed buddy this problem is with all Dmax !

 

So what year is yours?

 

my 03 does it occasionally. always starts the second time.

(for you who say that its a flat spot on the flywheel)
if there is a flat spot on the flywheel, then how does it always start the second time?

mitch

 

My 04 lly started doing it ~65K, always engaged on the second try, replaced the started, now have 130K on the truck, only did it once since replacement.

 

My 04.5 is now grinding about 1 in every 10 or so starts. Really starting to get annoying. Starter is fine, bolts are tight....I have no idea what else to try. Sounds like getting a new starter doesn't help any, very frustrating.

 

try it , give a small starter shot before starting the engine ! this help the bendix to place on the flweheel before it is spin at full speed !

 

when you give the short starter shot you will hear if the Bendix is engaging correctly or not, if the bendix is not engaging , give another another starter shot until the bendix engage correctly.

because some flywheel have some wear due to starter pignon grinding, during the first month you will use this procedure, the bendix should not engaged correctly sometime .

after some time the wear should reduce and the starter will engaged every time you give a shot before starting !

before using this procedure my starter grind every 10 start, now my starter never grind anymore !

 

So doing this will reverse the wear on the flywheel..? I can see giving it the quick shot helping to prevent the spinning but its not going to reverse any damage already done.

 

this is only a way to prevent your starter from trashing your flywheel !

 

If you guy want to go farther, there a way !!! ,

Use an auxiliary starter relay to manually control the starter motor

1- Disconnect your starter motor from the bendix solenoid
2- Add a second starter relay with auxiliary start push button
3- Connect the starter motor to the second starter relay.
4 -Use your key switch engage the bendix
5- Use the auxiliary start button to spin the starter motor

 

If you guy want to go farther, there a way !!! ,

Use an auxiliary starter relay to manually control the starter motor

1- Disconnect your starter motor from the bendix solenoid
2- Add a second starter relay with auxiliary start push button
3- Connect the starter motor to the second starter relay.
4 -Use your key switch engage the bendix
5- Use the auxiliary start button to spin the starter motor

Never thought of trying this. Not a bad idea, think I might have to try it.

 

i do not think it will reverse the wear of the flywheel but i try to explain

we know that the starter pignon is doing wear on the flywheel when is grinding from an unsuccessful starting attempt

on a successful attempt , when the starter pignon is engaging correctly it flatten some wear.

 

I had this problem when my 2005 GMC 2500 was new. dealer replaced 2 starters and grinding problem did not go away. Finally the dealer received infor from GM that many of the flywheels were slightly off specs from mfg. Dealer then replaced flywheel, and then the 3rd starter because teeth on second where also ground down. Have not had a problem with it since (over 120,000 miles later). Go after GM! This has been a problem since 2004. Good Luck

 

Have not had a problem with it since (over 120,000 miles later)..... Go after GM! This has been a problem since 2004. Good Luck

Glad they came good on it.
Starter grinding was a problem on an '02 D/A that I once owned. This has been going on way too long.