It almost sounds like there may be such a wide tolerance for "slop" in different aspects/parts of the replacement modules that it is causing fitment problems when the parts are way to the far edges to what they considered within tolerance.

It would be interesting to have GM ship your dealership an ignition from a different area of the country (different lot, made on different day, etc) and see if it isn't something silly like a bad lot of ignition cyls sitting at your dealer, giving you defective after defective cyl from the same lot sitting in the same bin.

 

ever get this solved, Toot?

 

Not with the dealer. I went to the car one day and done some snooping at the starter and noticed someone (not I or a family member) had been beating on the solenoid of the starter.

Dealer never mentioned anything about the starter have these markings.

I needed to go get a starter for another car so, I went to a local pick a part a few weeks ago and lucked up on one the was recently put on the lot and it had a pretty one on there (newly rebuilt unit).

Installed that starter and it has started ever since (fingers crossed).
Seems like the dealer would have suggested a starter replacement. Total cost for that starter was $20.10 can't, beat that.

 

Other than a five finger discount, no I'd say you did pretty well

 

You been hitting Pull-A-Part on Centennial without telling anyone, Tooter? LOL