Club 80-90 Forums

2 ltr Aircooled Autohomes Hi-top

Yesterday my starter made the grinding noise a few people have mentioned previously. After a second or two of noise the starter stopped trying to turn the engine over altogether (never happened before). Luckily the van bump started and got me home. I had a look through the forums & wiki and the starter bush or sticky pinion appeared to be the prime suspects.

This morning I tried to start the van in case the T25 fairies had fixed it during the night but the starter motor didn't even turn over. The relay behind the glove box clicked, but I couldn't hear anything from the solenoid or starter. The battery is charged, and if I turn the key with the headlights on they dim, so power must be going to the starter. I've taken the starter off now and it all looks Ok? The pinion is free on the shaft, the bush in the flywheel housing looks ok, so now I need so help.

First question, when I took the wiring off the solenoid there was a "spare" spade connector? I've labeled it 1 in the photo below. Is anything supposed to be connected to it?
Second question, can I test the starter motor on "the bench"? Can I put the starter in a vice and connect a battery across the solenoid terminals and earth the body? I'm worried that having nothing supporting the "bush end " of the shaft could damage the starter or even have the pinion launch itself off the shaft?

I'll get a new bush & fit that anyway now the motor is off, and clean the terminals on the solenoid. Is there anything else that might have cause the starting problem?

By the look of the starter, its been on there a long while. Your best bet would be to swap it for a reconditioned unit. If it was a little newer I'd have a go tackling it myself but on one that old, you'll save much grief and time by replacing it with something more lively. If you do get it functioning again, chances are it'll give up the ghost when you're knee-deep in snow, as all starters seem to like to do as they reach their autumn years. You may find a local place that could rebuild it for as little as £40 - depends where you go.

I'm a great believer in recycling items and making things last longer (check my posts) but on a vehicle as heavy as these are, you don't want to be stuck in the winter having to push - it ain't fun .

The other terminal is an earth wire - not required.

Thanks for the quick reply. I had a a closer look at the starter earlier and a re-con sounds like the way to go. I took the solenoid off and when the pinion dropped forward it was followed by a stream of oil? I ran the van for a year with an oil leak that was finally cured when the crankshaft seal was replaced. I guess that the flywheel gradually filled the starter motor with oil that had found its way into the bell-housing. I drained out the worst of the oil and found unsurprisingly everything moved pretty freely! The problem seems to be that the commutator and brushes are badly worn.

I think the combination of oil contamination & wear mark the end of the line for this starter. I found a local place that will do a replacement for £75 so its time to raid the piggy bank.

Ingore this post.... Didn't see all of the photo as kindly pointed out below!
That spare spade connector you have labelled No.1 is for the red cable running from the ignition. Without it the starter will never turn over when turning the key. The wire has probably fallen off. This connector can cause problems on these starters and is usually the first place to look when having problems.
The wire will be dangling down somewhere near the starter!

Except that its not. Its No 2 that will go to ignition. No 1 is on the same side as the earth strap. Scroll the picture down.

You're not wrong! Didn't see the rest of the picture... Doh!
Thanks for that CovKid, will amend my above post...

Fitted the new starter this morning. Normal service has been resumed. Hopefully it'll last as long as the old one.