I have had intermittent staring problems also, jsut a click and no action. I found that if I put one foot on the clutch, in 1st gear (or reverse), stretch out the other foot giving the whole truck little push/rocking it , then release the clutch. Almost like a roll-start, but the starter/flywheel just needs a bump to get going again.
I found this works just about every time, total PITA and not a real fix, but it saves you running around looking for someone to boost you.
(if you got a lift and short legs,this can be difficult....)

I am rebuilding my engine right now, and had the starter out. It was not really that worn, just very dirty, not sure if cleaning it will help, I hope so. The starter bench-tested great, but it's an intermittent problem, so hard to tell from one test..

Good luck!

 

I am only 5'1 so no I cant just rock the truck like that I need to figure out what it is or I'll ether sell it or non op it. I rebuilt the engine from the ground up last nov and have replaced everything that was tired except the leaf springs/shocks.

 

Sounds to me like you need to actually check this stuff with a multimeter, looking for continuity to ground as well as to other connections farther in the food chain.

I don't have a high post count, but I build amplifiers for people, so I have a background in electrical troubleshooting. This crap isn't actually HARD, but it's frustrating as hell!

Must be a spot on the starter motor you can clip a meter to, and see exactly what is happening down there when you turn the key...? You need to know what SHOULD get 12v when you turn to 'start', and why it's NOT. So you move back up from the starter to the harness...eventually it goes back to the switch.

Better yet, how about taking the damn ignition switch out, and continuity testing/measure voltage thru its different positions? That would tell you right off if it is the switch...

I'd do a few of the things suggested above - good advice. Jumping the starter to see if it's still ok, then you can move on to the wiring/switch BS.
Hope you get it goin', man, sounds like you put a lot of work into it!! Keep on trying...

 

Well I am going to replace the switch anyhow, I hit a bump today and my key fell out I didn't even relize it until I got home.