Starter Motor Jamming (probably my fault)

[Dubwana]

Hi:

I just rebuilt my starter, new brush holder, bushes, clean up etc. It turns fast but in the morning its inclined to jam a bit, a few times then it fires the 1.6D into life. I obviously made an error in assembling. I can think of two things that I did that could cause it and before I take it off in the morning was wondering if anyone had an extra observation:

1) I took up some extra slack with an extra washer at the brush holder end. Could this make it a bit too tight?

2) I didn't but any oil or grease on the bendix shaft, being afraid that it would collect dirt and make it jam... should I have? It was dry when I took it off and I left it that way.

I'll dismantle it in the morning but thought I'd just see if there is anyone who could point me in the right direction

Thanks,
Dubwana

[Oldiebut goodie]

Another brush holder? - didn't you replace it a couple of years ago, I seem to remember chasing around for part nos.
I should say that you have answered your own question - I would say that you have made it tight with that extra washer. Did you test it before you put it back on the van? When you say 'washer' I have visions of a great big fat washer rather than a shim of far smaller dimensions
They should be dry, oil will only collect all that dust that you like to drive in.

[Dubwana]

I'm impressed by your memory and thank you again for your work, its still helping me. Yes, another brush holder...

I had to rebuild the starter again a disgustingly short period ago, the bushes were worn and I had to get them manufactured locally. It looked good but they wore out in a couple of months and the whole thing inside twisted, pulling a tin brush holder out and busting it up. Fortunately I had been extra careful and purchased a spare one last time I was in the UK. So, this time I think I went too far on filling in all the slack in a paranoid over reaction. I've just come home so am letting it cool down before I pull it out... again.

Thanks for the oil advice. Its what I did but as you can see I'm starting to doubt myself

Thanks again for your help...

Dubwana

[Dubwana]

And yes, I did test it. It worked great. I think when I said "jamming" I should have said not engaging properly. It's like it connects turns a tiny fraction and then disconnects. I'm thinking I made it just to stiff inside for free movement. Once it turns, it spins great. Oh well, another Sunday to learn some more mechanics...

[marlinowner]

I thought Eldoret rings a bell, back in the 80s we visited my sister-in-law who was working as a teacher in Kenya near Mount Elgol - taking the train from Nairobi to Bungoma - thinking we might have changed trains at Eldoret?

[Dubwana]

I thought Eldoret rings a bell, back in the 80s we visited my sister-in-law who was working as a teacher in Kenya near Mount Elgol - taking the train from Nairobi to Bungoma - thinking we might have changed trains at Eldoret?

that was a long time ago, no passenger trains now but if the government has its way you will be able to come back and travel from Mombasa to South Sudan... if you feel so inclined!

[Dubwana]

Another brush holder? - didn't you replace it a couple of years ago, I seem to remember chasing around for part nos.
I should say that you have answered your own question - I would say that you have made it tight with that extra washer. Did you test it before you put it back on the van? When you say 'washer' I have visions of a great big fat washer rather than a shim of far smaller dimensions
They should be dry, oil will only collect all that dust that you like to drive in.

I got it off, everything that I put in was OK, no worries, no big mistakes. But I'd got an engineering workshop to make the bushing... the one at the front still looked goodish but the rear one was worn like crazy, filings all over the place.

Now, they made it from copper, I'm now thinking it should have been something harder, could you kindly advise me if I go back tommorow what I should get the new bushings make out of? I'm pm... ing

Thank you for your help,

Dubwana

[CovKid]

Phosphor bronze I think although that may well be what they used. Unlikely to be copper.

[Dubwana]

Thanks, I'll go and try to see if I can get anything better tommorow. I have a spare starter but its for a newer engine, it fits, is quieter, smaller, lighter, but doesn't get the speed up that I need for this engine. So its a bit hit and miss. Hopefully I can get them made,

Thanks for your help

[marlinowner]

We actually flew to Kenya with Air Sudan in an ex-Egypt Air 707 and made an unscheduled stop in Juba where there were youths lounging around with various firearms - I was pleased to take off again! A week later civil war broke out in Sudan and Air Sudan was grounded, coming home in a Kenyan Airways 747 was more relaxing...

Would have thought something like phosphor bronze for the bearing.

Tut too long replying again

[marlinowner]

We actually flew to Kenya with Air Sudan in an ex-Egypt Air 707 and made an unscheduled stop in Juba where there were youths lounging around with various firearms - I was pleased to take off again! A week later civil war broke out in Sudan and Air Sudan was grounded, coming home in a Kenyan Airways 747 was more relaxing...

Would have thought something like phosphor bronze for the bearing.

Tut too long replying again

[Dubwana]

Thanks, I'll go and try to see if I can get anything better tommorow. I have a spare starter but its for a newer engine, it fits, is quieter, smaller, lighter, but doesn't get the speed up that I need for this engine. So its a bit hit and miss. Hopefully I can get them made,

Thanks for your help

[Dubwana]

We actually flew to Kenya with Air Sudan in an ex-Egypt Air 707 and made an unscheduled stop in Juba where there were youths lounging around with various firearms - I was pleased to take off again! A week later civil war broke out in Sudan and Air Sudan was grounded, coming home in a Kenyan Airways 747 was more relaxing...

Would have thought something like phosphor bronze for the bearing.

Tut too long replying again

Thanks, this is very shiny and looks very coppery, its just shaved off in filings.

Yes, Juba. Lived there most of a year. No power for months, generators constantly failing in 40-50C so not even a fan. Got there just after the civil war and it was a very peaceful place... till the ammo dump blew up on us and it reminded me of my Dad's stories of the blitz...

[Oldiebut goodie]

Copy of the PM - so that others can see what is going wrong:

They are usually made from sintered bronze, basically a type of brass that is porous so that it holds lubricant within it. If it were made from copper I would expect it to seize easily as it is too soft and doesn't contain any lubricant. You would be better off finding a starter that you can cannibalize for a bush with the correct bore for the shaft as if you drill out a bush you can seal up the porosity so that it ends up unlubricated. Turning the outside down wouldn't matter in that respect. (I am wrong in that respect as it could impair the capillary action)

Take a look here on this page - that explains what happens. http://www.lm-tarbell.com/machining_sintered_bronze.htm" onclick="window.open(this.href);return false;

[Dubwana]

Thanks, now I understand why the manufactured ones didn't last: wrong material!

Before I order, this says that it is listed for a 1.6 D transporter but it looks like the petrol one too so I'd appreciate advice if I am looking at the correct item.

Thanks

Dubwana