Yeah before throwing parts at the vehicle, diagnose it with what you have on hand to try to eliminate stuff.
Like the quoted, I'd try to bench test the starter first beforehand as it may be a sticky solenoid.
Its been a while but from trying to remember:
- remove the starter
- to test the engagement (solenoid part, internal drive gear popping out), use a good set of jumper cables & attach the positive lead to the positive terminal of the solenoid to the positive of the battery
- then attach the negative from the battery to the negative on the solenoid
- the gear should pop out without spin
- to test the full engagement (drive gear popping out plus rotation), use the same connection as above & get a thick plastic coated handle screwdriver (wear gloves, safety glasses), & go across the positive & negative leads on the solenoid
- the drive gear should pop out & spin
- to test the drive gear for spin, attach the positives as above, then ground the negative on an unpainted part of the starter housing
- you should hear internal drive gear spin (but not pop out)
Remember to place your foot on the starter as it has a lot of torque.
Hope that helps.
I had this happen to me when I repalced the starter in my 71 fj40. It turned out to be a sticking solenoid on the starter. I exchanged the starter and no problems.