Looking for opinions from other mechanics. I am a retired mechanic myself but a little frustrated.
I have a 1988 for truck with a 302 engine. The starters in these trucks do not have a starter solenoid all of the power for the starter runs through the starter relay on the fender wall. The problem is the starter stays running sometimes. The contacts on the relay are welding themselves together and sticking closed.
In the past I have always fixed this by locating and correcting an excessive current draw usually caused by a bad ground, too small of cables or a dragging starter. I have replaced all the cables with 2.0 and also replaced the starter and used a heavy duty relay. Battery is also new. Problem still exists.
History, I had the engine overhauled a few years ago and only have about 200 miles on the truck since. I suspect the motor is a little tight but it does turn over easily. I am starting to think now tht my only option is to see if I can find a starter that will match that uses a starter solenoid on the starter or possibly installing an extra relay on the fender wall to reduce the load on the first one. I have never had to do this in the past but I am at witts end. Any opinions or possible solutions?