[Poppy]

If you are referring to the item in the bottom picture with the two brass bolts sticking out, that looks like your starter relay.

[GoalieFergy53]

Since it sounds like it'd be a P.I.T.A. to get a whole new wiring assembly from the alternator to the starter relay, I'm thinking I might first start by doing a " Big 3 upgrade ". Now that I know where the grounds are and the fact that cleaning them didn't help, I'd just rather replace them with bigger wire and know I won't have to worry about them for a while. I'm gonna pull out the wiring harness from the alternator to the starter relay and replace the positive wiring to the alternator. I'll either then see if the other wires & connections to the alternator or rebuildable by myself (or someone else) or if I'd just need to buy those as an OEM replacement.

As for wiring, right now it looks like it has 4 gauge, I'm thinking of replacing it with 0 gauge for better current flow and rather have overkill to play it safe. Has anyone done a Big 3 upgrade and have any tips or suggestions?

[GoalieFergy53]

I apparently bought the last New Old Stock starter relay-to-alternator wiring harness in the Country (according to two different dealers.) Got quoted $150 for it by one dealer, $250 by another but bought it from the dealer who actually had it and they charged me $45 + shipping! Score!!! I got it hooked up today and it still didn't fix my Low Amp issue!

Anyone have any suggestions? I think my next step is checking/replacing positive wiring starting at the positive battery terminal. I swear it's like I'm living in the Never Ending Story!

[GoalieFergy53]

Well it's time to get back to work on my bus again after putting it on hold and having another hip surgery. My next plan of attack is to replace the postive battery cables. I see that the OEM positive wiring has both the wire to the starter relay and the wire to the started soldered to the battery terminal. I got a replacement terminal cable that runs to the starter relay, but need to get one that runs to the actual starter.

Where exactly on the transmission bellhousing is the starter mounted? Is it something I can access from above with the doghouse cover removed or can I only get at it from below?

[Dominick]

I would say from below
If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
Disconnect the wires leading to the solenoid terminals.
To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
Loosen the starter mounting bolts and remove all but one.
Support the starter while removing the remaining bolt.
Then pull the starter out and away from the flywheel.
Once the starter is free, remove the last bolt and the starter.
Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear

[GoalieFergy53]

I took a look and saw the complex routing of the battery to starter cable and was in no way gonna be replacing that unless I absolutely HAD TO. I bought a military style battery terminal, replaced the positive battery to starter relay cable, put a new cable end lug on the positive battery to starter cable and on 2 other cable ends that attach at the positive battery. I also tightened the alternator belt a bit more and when I started it up everything was back to normal. WOO HOO! I can finally say case closed for this thread!

[Dominick]

Great