I ordered a new starter, arrives today.
I thought this would be worse than the emission delete job, but so far the removal was cake. I jacked up the Jeep and removed the drivers front wheel. Placed the drivers jack stand on the frame to give plenty of room under the starter. I already had removed the two skid plates when I did the emissions delete and left them off as most of the sensors that get wet or damaged are gone now. I only used three tools for the actual starter removal. A 15mm ratcheting wrench with flex head, a 1/4 drive 13mm socket and wrench and a 15mm socket, wrench and short extension (I only had 1/2 drive on hand which worked perfectly.
Using 15mm ratcheting wrench remove the top nut of the drivers motor mount. Use floor jack with small block of wood under drivers side of aluminum oil pan and jack up a couple inches. There are two 15mm starter bolts holding the starter in place. One on the engine side and one on the transmission side. Using the same tool, remove the starter bolt that you can see that threads from the engine side through the starter and into the transmission housing. Now use the 15mm socket, wrench and short extension to remove the starter bolt you cant see from the transmission side. If you look at the transmission housing where it mounts to the engine you can easily see where the case has indentations to allow for bolts. So you know where you removed the engine side bolt and if you go up from there you will see the indentation for where the bolt is. Just reach up there with the tool and you'll be surprised how easy it is to remove. Next grab the solenoid and pull to unseat the starter. I needed to jack up a 1/2 inch at this point to get the starter all the way out of its location, but still up there with the wires connected. Now move the starter enough to see the nuts on the front of the solenoid. There are two wires to remove, the small one was just a squeeze clip, so squeeze and pull it right off which also makes more room for the two nuts. The two nutsy are 13mm and I found my 1/4 drive socket and wrench worked perfectly. The two nuts hold the same big positive wire to the solenoid. After that I slid the old starter out the rest of the way. The install should be as simple.
I'll post again if the new starter does NOT fix the problem.
LittleG