start motor trouble - rounded hex head removal

[CovKid]

or new solenoid

[mbcamper]

Who sells the starter parts? My usual Brickwerks supplier only appear to sell complete recon units.

[Oldiebut goodie]

It strikes me that your checking of electrical connections is very suspect - the two male spades on the solenoid are corroded to hell . I am surprised that you ever got it to work! Even a slight cleaning would have improved your chances of it working correctly.

[mbcamper]

Point taken about the solenoid contact. I've searched for parts for the starter motor and suppliers are geared up for reconditioned units.

Given I want to get it reliable I think one of these reconditioned units is called for. Now my DG engine is in a 1986 van and it appeared that they changed the starter motor sometime after, so it looks like this is what I need:

http://www.carparts4less.co.uk/cp4l/c/V ... 15e&000308" onclick="window.open(this.href);return false;

It terms of dimensions it matches.

The other alternative was this which appears to be for a later model, and Im assuming they are not interchangable:

http://www.carparts4less.co.uk/cp4l/c/V ... 0c7&000308" onclick="window.open(this.href);return false;

I'll talk to the supplier on Monday but wondered if anyone had experience of these parts. From the pictures they are sold by other suppliers such as Brickwerks, JK etc, but not so competitively priced.

I'll also make sure that I replace the bush and replace electrical connectors where needed.

Thanks

[marlinowner]

https://club8090.co.uk/wiki/VW ... rter_motor" onclick="window.open(this.href);return false;

[Smiffo]

Point taken about the solenoid contact. I've searched for parts for the starter motor and suppliers are geared up for reconditioned units.

Given I want to get it reliable I think one of these reconditioned units is called for. Now my DG engine is in a 1986 van and it appeared that they changed the starter motor sometime after, so it looks like this is what I need:

http://www.carparts4less.co.uk/cp4l/c/V ... 15e&000308" onclick="window.open(this.href);return false;

It terms of dimensions it matches.

The other alternative was this which appears to be for a later model, and Im assuming they are not interchangable:

http://www.carparts4less.co.uk/cp4l/c/V ... 0c7&000308" onclick="window.open(this.href);return false;

I'll talk to the supplier on Monday but wondered if anyone had experience of these parts. From the pictures they are sold by other suppliers such as Brickwerks, JK etc, but not so competitively priced.

I'll also make sure that I replace the bush and replace electrical connectors where needed.

Thanks

Place a `wanted` add on the site.
Lots of people have spares lying around, so that might prompt them to sell one.

I remember seeing a reconditioned unit advertised by a bloke in Peel on the Isle of Man some months ago, he only used it a few times then went the Subaru route, and it may not have sold...

[mbcamper]

The link answers my question - thanks for that. They can be swapped after all. It probably explains why Brickwerks only sell the larger one.

In the mean time I've removed the bush using the M12 tap technique which was quite easy. Basically you screw in the tap which runs right down the bush and when it gets to the end it pushes the bush up and eventually comes out.

[Jawin89]

Solenoid available from here:

http://www.cps-service.co.uk/product_in ... rter-p-371" onclick="window.open(this.href);return false;

[CovKid]

Aye, and about the going rate (under £30). A lot of starters get binned that only need brushes or a new solenoid. The REALLY hard bit is getting the old solenoid off. Even with an impact driver you may be forced to drill them out and fit new screws. I always felt they should be bolts but they're countersunk.

[mbcamper]

Well I managed to remove the solenoid and also took the starter motor apart so I could inspect the brushes. The brushes were quite worn but the communicator on the motor was in a very bad state with hunks missing out of it. In this state, I don't think it would be reliable so I've taken the plunge with a replacement starter.

It came with a new bush which I soaked in oil for 24 hours before drifting in. The motor its self went in easily and I've assembled with copper grease on the threads which always helps if ever you end up removing it again in a few years time.

So onto the electrical connections, the battery cable was cleaned up and the alternator cable was terminated with a new ring connector. All fine so far. I didn't like the look of the starter spade connector so I cut it off with the intention of replacing it. However when you expose the cable it's all blackened inside the insulation.



I could keep cutting it back, but I suspect I'm going to end up replacing the cable as it will get too short. Looking at the wiring diagram it looks like D24 is near to the starter switch.



Now I've embarked on the job of making it reliable I don't want to cut corners, so was wondering what others have done with this?

Thanks

[Oldiebut goodie]

Rub some flux into the blackened piece piece with your fingers and it will clean off ready for soldering although if it is easier replace back to the nearest connector if you can find it.

[CovKid]

Actually, this may be an occasion when the vinegar treatment may work quite well.

[mbcamper]

Okay some success! I smeared some plumbers flux on the cable last night and then washed it off with vinegar followed my water and the end result was quite pleasing! Shiny fresh copper wire and I didn't need to cut the cable any further back which saved me another job.

So I've terminated it with a new spade connector (soldered and heat shrink) and reconnected the battery ready to test. On the first attempt the solenoid clicked but it didn't turn. 2nd and every subsequent attempt it worked fine. Maybe the first attempt was just a blip of the starter so I'll have to monitor it.

Like every "little" job it was a little more of a faff than I originally thought, but I'm back in action for now.

Thanks all for your ideas!

Mark