2000 f150 4.2L starter issue
 

I had my starter replaced replaced with a rebuilt from autozone (I supplied it as I was going to replace it myself), I couldn't get a rounded bolt off so I had a shop do the work. Picked it up, started with no issue for a few days then I guess about 5 days later I heard that dreaded CLICK when I turned the key. After a few turns it started SO later that day I replaced the solenoid and thought I had fixed it for a day and a half but.... Nope. So I've resorted to tapping the starter, (jumping the solenoid didn't work) which has been a pain in the ass. I will call the shop but I'm curious what you's think.

On a side note it was raining and gloomy out and I had someone turning the key as I tapped (with a rod to reach it and a hammer) the starter, and I could see sparks every time he turned the key until it turned over. Wondering if it could possibly be a wiring issue?

There is a good possibility when they tightened the wiring connections at the starter the connections moved are too close to one another or might be loose. It's worth to get under there and have a quick look. If there was anything wrong with the starter ,which could have a problem, I don't believe you would see any sparks unless the starter is coming apart.