Did you ever get your starter sorted out? Just saw your post.
I had a similar problem about a year ago...attaching a grounding wire from the starter to the battery ground fixed it till now.
Problem came back yesterday as soon as I loaded a rebored block in the bed of the truck...literally the truck wouldn't kick over at the machine shop. Checked the battery and it was good at 12 volts across the posts. Got a jump anyways and it turned right over. Won't turn over when I cross the 30 and 50 posts with a jump wire though on its own battery? Maybe the starter is worn out and binding?
Very strange...VW's.
Will clean all the contacts up and try again with an extra starter...if that doesn't work then maybe replace the transmission bushing too?
VW's
:?
If you're using a little gasser battery it definitely won't turn over consistently. If you compare starter sizes between say a ... dodge neon and any diesel the starter is at least 2X bigger on the diesel. You need loads of juice for it.
The battery only as big as it is because we need a mother of a starter to make that large compression quickly. Find a friend with a diesel truck and ask to use the battery off that to see if it starts better/consistently.
Got a big over sized battery in there...but is it is on like month 65 of 75.
Wondering if it is charging low. There have been a couple of wiring issues lately. All at once the gas gauge and temp gauge when out, the hazard light relay started buzzing and the signals went out, and the alternator charging light went on very bright.
Thought it might be the voltage stabilizer on the back of the instrument panel, so I changed out the panel and the problems went away but the alternator light has gone dark.
VW's :?
Maybe the circuit for the alternator light is bad because the alternator checks out okay. If the alternator light circuit actually controls if the alternator charges the battery and the battery is under charged just enough that the starter won't turn (returning to the original subject).
But if you are reading this you understand :wink:
VW's :?
Appears to have been a loose connection with the blue ground (?) out of the alternator harness to the alternator light. Seems like the alternator is a strange place for a ground to run...I've got alot to learn :wink: