I'm hoping someone else has experienced and solved this. I have a 1995 Cutlass Supreme Converitble with the 3.4. I bought the car 1 1/2 years ago with 44,000 miles and it now has 50,000 miles on it. The car is stock and has no visible signs of tampering, electrical or otherwise. It's in nice shape and was a California car...no rust anywhere.
For a while I was experiencing starting issues that seemed like a weak battery...engine was very slow and labored to turn over, just like a weak/dead battery, but the battery was new and tested fine. Shortly before I replaced the starter, the car began occasionally blowing the starter fuse (5 amp located in the dash fuse panel) when starting the car with a warm engine. I eventually replaced the starter with an old-stock GM rebuilt unit I purchased off of ebay. The new starter seems perfect and solved the slow turn-over condition. I also thought it would solve the occasional blown fuse too, but it hasn't. In fact, the fuse is blowing more and more often. It rarely (if ever) blows the fuse when the car is cold, but often does it if warm. When it blew in the past, it would often blow before the starter energized. I experimented with putting the car in neutral to see if perhaps the transmission range switch was the culprit. That seemed to make some difference, but the fuse is still blowing. Now, the starter will engage and start the car, but the fuse will blow during the starting process...starter stays engaged and starts the car.
I removed the transmission range switch, took it apart, cleaned the inside and but it back together. There was minor corrosion on the inside of it so I figured that it was the problem. After reinstalling it, it does the same thing. I guess it could still be a faulty range switch, but before I replace it I wanted to see if anyone else has ever experienced this problem. I have the GM shop manuals, and the only other thing in this circuit is a theft deterrent relay and a theft deterrent module.
I appreciate any help or guidance.