wow, sounds familiar. Few years back I had trouble with the starter on my Ford 755 b/h. Cleaning the posts would get it to work for awhile then it finally quit, wouldn't start, no matter what I did. Rebuild cost about $100. Came back all shiny and clean. Worked for a while again and then quit. Frustrated, I pulled out a meter and happened to check for continuity between the starter housing and the negative post. Nothing. I took it apart and removed the bolt from the inside that served as the neg stud. It was pretty grimy underneath the bolt head. Rest of the housing interior was clean as a whistle. I wirebrushed the bolt and scraped the housing down to bare metal. Put it back together, b/h fired right up and been working ever since. Best I can figure is that the jam nut that held the bolt in place had loosened up at one point and allowed dirt to get behind the head of the bolt.
If I had a dollar for every $100 I've wasted over the years, I'd be rich.
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