Hey all,
As I may have noted before, I am an old Dodge guy and had no previous experience with Chevy's (other than getting my first speeding ticket in a 69 Chevy Chevelle when I was 16) so I don't know what to look for in an 1986 GM square body. I know Dodge starters could lock the solenoid, but I don't recall a Dodge starter ever having an issue like this.
After a frustrating time with the starter, we decided to purchase a new one. The second the guy at Oreilly's asked if it was manual or automatic, I knew what was wrong. The starter was from an automatic trans, which has a deeper reach than a starter for a manual. I don't know the tooth count on the flex plate we installed but I believe what was happening was the starter was engaging with the flex plate and getting stuck in place. I think this meant that when it locked, it wouldn't let the Bendix spring and gear fall back and that kept the connection between the battery to the starter motor engaged, keeping it cranking. It is the same as a starter that lacks the shims, but from what I have read online, that sticking typically happens when the motor runs, driving the starter gear but not leaving it engaged. Maybe they are the same thing?!?
Am I on the right track here?
Anyway, new starter and the engine is running. Now I am working through getting the engine to sing.
Thanks to all of you for the input and suggestions. It's really great living in community of good folks like you all...