Greetings gentlemen.

My wife'* GP was starting very weakly and then quit altogether. I eliminated the battery and alternator and diagnosed it as a bad starter. One of my clues was that white smoke would instantly billow from the starter when the key was turned to start. A bench test at O'Reilly'* confirmed a bad starter.

I buy a remanufactured starter, install it, turn the key.......CLICK.......HUMMM.......nothing.

I add shims.......CLICK.......HUMMM.......nothing.

I have my wife turn the key while I lightly tap on the starter with a hammer. Sparks shower off the starter every time I tap it, but after a few tries it starts up (kinda scared the hell out of me, actually).

Starter sounds good and strong. I turn the car off, start it a couple of times, then on the third start.......CLICK.......HUMMM.......nothing.

I shouldn't have to be tapping on a brand new starter. I'm going mad trying to figure out what the deal is. Maybe I got a defective unit? Maybe I'm a defective unit? Any help would be appreciated.

Take it back in. This sounds like an internal issue with the starter. Have them bench test it.

Auto Zone sold me a dud starter.
Swapped it out and she'* back on the road.
I could change out that starter with my eyes closed now.