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Hey Roger,
I have a Lock-Right (same design as the Spartan) in the front of mine and I've been happy with it. I don't drive it on the street in 4wd but it works great on the trail. I run with the hubs locked and front twin stick in neutral and just engage the front when needed. I have never...
That should fit the old/original style starter not the gear reduction type this thread is talking about.
Also at that price, I would just get a new gear reduction type. They are better in every way, that's why all the newer trucks use them.
I think someone makes a tapered insert that should fix your problem with those steering knuckles. I can't remember who but maybe someone will know the vendor.
Like others have stated, you should be able to pull all wires (there should really only be one wire) off of that "I" terminal and the engine will still run. If not something is wired wrong. It should also still start with all wires pulled off the "I" terminal, but maybe not as well.
I bet DirtDonk is right, the PO probably over tightened it. Just back it off a 1/4 turn, drive it and see if it gets any better, repeat. If it gets better then go through the proper procedure and re-adjust it.
It's been years since I hooked them up so I don't remember the color of the wire. I'll try to look under there tonight and see if I can see where it's hooked up.