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Sounds just like a hot start issue. Either wrap the starter or get a shield for it. You seem to have checked everything else. The only thing I can think of that hasn't been mentioned is the cranking amps of the battery. As a starter wears or when it is hot it requires more amps to turn it. Alot of the 3/4 tons had factory "heavy duty" starters which also require more amps. Just some things to think about.