Help replacing starter trigger wire

[agnew1985]

Hi everyone. I have an intermittent starting fault which I think might be cured by replacing the starter trigger wire. However, I am a complete ignoramus with electrics! I have got 5 metres of cable and plastic conduit all ready to run but I've got to the fuse box and got stuck! I would be really grateful if someone could tell me how to remove the wire from the plastic connector block and how to put it back again! Thanks in advance for any help,

Nick

[Jawin89]

Simple answer is you can't. The end of the wire has a terinmal crimped to it. This terminal is then pushed in the plastic connector and it locks in place. It can be removed with the use of a very small flat screwdriver, jewellers type, but they cannot be reused. You would need to source a new connector. Are you sure it is the trigger wire that is at fault ? Have you checked the connectors on the starter, they all need to be tight even the spade connector.

[Oldiebut goodie]

Of course they can be re-used - I do it daily! (not that you would want to in this case with a new wire) All you have to do is raise the tang back up and remove the wire where it is crimped. Many is the time that I have done it when a replacement terminal isn't to hand.

[Jawin89]

I have never had your luck then as they always end up bent or distorted. I'm probably using the wrong size of hammer

[Oldiebut goodie]

Insert chosen jeweller's screwdriver - turn it 90 degrees to depress tang, use another screwdriver for the other tang at the same time if you are removing jpt terminals and the like.

[pirate-pete]

Your jewellers screwdriver should be fine to raise the tang. I've not really had problems with these either. There is probably a proper tool too if you look around. Used to have one for smaller electronic connectors that was just a hollow tube that slipped over the prong and released the tang.

I'll second the bit about checking the connection on the starter. The spade on the starter can wear so the connector is no longer a good fit. The solenoid can also give these problems too. Had that too but since swapping the starter a couple of years ago have had no further problems. Still have the old starter somewhere and hope to dismantle and identify what the actual problem was. Temp cure was to tap the starter with a hammer but not so good when it fails when you are first in queue for the eurotunnel and van is fully loaded inc bike rack to slow down access

[bigherb]

I'm assuming you have the later fuse box then you need the correct round tool to push in the tangs. either buy one from Durite like the one at the top or you can make them out of brass tube like mine the lower ones.

[CovKid]

It would see reasonable to assume that after 30 years the trigger wire can deteriorate much like the main starter cables although more often than not, its a faulty ignition switch.

[agnew1985]

Thanks so much for the replies. Should probably have given a little more history. I have had this problem for about 2 years but it was bearable until some serious engine surgery which has taken me off the road for some time. Now I'm trying to get it back on the road the problem has reared its head with a vengeance. To cut a very long story short, I have replaced the starter which I know is working as I bench tested it (I know, I know I shouldn't have but I didn't realise till afterwards!), replaced ignition switch, replaced the spade connector at the starter end of the trigger wire (although I have to confess it isn't soldered, but since this is an ongoing problem I don't think this is the answer) and cleaned all earths. The battery is good and always fully charged, I'm getting plenty of juice arriving at the main feed to the starter. Occasionally I can hear the solenoid click but the starter doesn't go but more often than not, it either cranks or doesn't (usually doesn't). I've actually been puting off replacing the trigger wire but I'm at a loss as to what else could be causing my problem. I have bought the replacement cable so am ready to go! So can anyone tell the best way to connect to the fusebox?!

Thanks again,

Nick

[agnew1985]

Oh, and yes bigherb, it is a late fusebox. I'm in a 1988 dg 1.9 autohomes 2 berth! Bloody love it! Will have a look at that tool. Does it remove it in such a way that I can put a new connector on the wire and stick it back in?

[CovKid]

Hmmm, can see your dilemma. I think I'd splice in a temporary trigger wire and test it to death. Its also not beyond the realms of possibility that the replacement starter (bench tested or not) has an intermittent fault on the solenoid. I've bought replacement starters that have been exactly like this. Very frustrating when you've paid a lot of money for a remanufactured unit.

You could fit a relay before the solenoid. I'm not a big fan of doing so since more connections create more potential failure points, but people do fit relays to minimise voltage drops.

If after running a temporary trigger wire the problem persists, pop the end cap off the starter and check that the braided wire is sound and properly connected and that the commutator is clean. Beyond that its likely to be a faulty solenoid.

[agnew1985]

When you say splice in a temporary trigger wire, do you mean stick a spade connector onto the end of a long wire, attach it to the starter then touch the other end directly to the battery and see if it cranks? I do feel like I've been going round in circles with this issue a bit. Just want to get it driving and there's something really elusive spoiling things!

[CovKid]

Yes, more or less. If its consistently reliable then by all means focus on the trigger wire but if its not, you'll know its likely to be starter itself (which may even be a simple fix) . If you've been going round in circles you need to nail the actual cause rather than try everything. Suggest you run this test at different times. It will still only crank via ignition key ofcourse.

[agnew1985]

Great. I'll let you know how I get on! Thanks again.

[agnew1985]

Well, I put a temporary line between the battery and starter trigger spade and it cranked every time without fail. This seems to confirm my suspicion about the trigger wire being past its best. Which brings me back to the issue of wiring into the fuse box. Does anyone have any advice on the best way to go about this? Unless there is another way round the problem?! Thanks for the advice so far.