GM-GMC: Starter, sierra 4x4, gmc sierra

Question
I have a 1995 GMC sierra 4x4 6.5 litre Diesel. I recently replaced the 2 baterries and all the wiring to them. I have check the voltage from them and the altenater as well as at the starter and all checks out perfect. 3 months ago I replaced the starter with a Champion rebuild. It failed last week and I replaced it under warranty. Over 2 days and after testing everything again the starter was dragging so I returned it and had it tested. It tested bad so i replaced it again under warranty. The vehicle started great twice then failed to start again at all. After testing everything thing again it appears to be the starter. I am beginning to think the Champion starters are all bad and I was going to return it for a refund and get a GM part. Is this my fault in anyway?  

Answer
Steve,

I have heard of problems with rebuilt starters, for all engines, out there.  For example, Auto Zone is supposed to sell junk.  Yet, I have had one of their direct-drive starters on the 6.2 diesel in my K-2500 for two years now without a single problem.

How long do you crank the engine before it starts?  GM 6.2/6.5 diesel starters get hot very quickly.  Prolonged cranking with the starter will shorten the starter's life.  If your diesel is functioning correctly, it should start nearly instantly hot or cold (with cold starts accomplished after the "Wait to Start" light goes out).

Did you get a reduction-drive rebuilt starter?  These starters, which have an offset in their housings, were developed to provide better torque to start the 6.5 diesels.   A direct-drive starter will fit, but it may not last as long as it should.

Did you put the front bracket (radiator-end of the starter) back on when you reinstalled the starter?  Without the bracket, the weight and length of the starter will cause it to flex and destroy the starter and/or the flywheel/flex plate teeth.  There have been cases where the vertical starter mounting bolts have stripped out and/or the cast iron has cracked or broken off where the starter mounts all because the front bracket was not reinstalled.

Lastly, check all your ground connections.  Not just the large ones running to the batteries, but the smaller ones that run from engine to frame, transmission to frame, and frame to body.  Remove the ground wires and clean up their ends and corresponding places where they connect on the vehicle with sandpaper.  Replace and wires that look marginal.