I am rebuilding the starter for a 1985 300 SD for the first time, so I may be making some dumb mistake. I tested it off-car with my jump-starter. The starter runs fine, but the drive pinion only moves forward about 1/4 to 3/8 in. I am thinking that to engage the flywheel properly, it should be moving all the way, or nearly all the way, forward to the shaft bushing. That would be about one inch of movement. I can manually move it that far forward until it is up against the bushing. I know that the solenoid, when energized, is working against the spring in the center...but it is the same spring that worked fine before.THe solenoid...or I should say starter relay (it mounts into the body of the starter)...is a new one. SO that would not be the problem. ANy idea what is wrong?
- posted
18 years ago