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?
On 24 Apr 2005 16:10:52 GMT, firstname.lastname@example.org (Clive Turnbull)
Yes, there is a fork that forces the pinion forward. I didn't give
much thonght to which way I put it in, as it looks like it is
symmetrical front-to-back. Im pretty sure it is, but I guess I could
double-check that. The top lever of the fork engages the spring-loaded
lever connected to the solenoid "plunger". Jim
If the solenoid plunger is doing full travel and the gear isn't, I would
have thought it must be something between the two and that only leaves
the fork, unless the solenoid plunger isn't going it's full travel.
Sticking in it's bore so to speak. Such a long time since I've done one.
Good luck Clive
On 24 Apr 2005 23:01:55 GMT, email@example.com (Clive Turnbull)
Yea it can only be that the plunger is not moving full travel, or
there is something wrong with the yoke. It is a brand new solenoid
(relay) assembly so unlikely to be that. Might take the center spring
out and see if that lets it push the pinion out all the way then.
Can't see what is happening inside. I noticed the new solenoid has a
black rubber boot on the front of the plunger that mates up to the
hole in the starter housing....the original didn't have this...maybe
that is interfering with the plunger travel somehow? I am not sure why
this is needed....as a moisture seal? Thanks, Jim
Could be the seal stopping the travel as you say. Anyway you could do a
test without it. It is just to stop rubbish getting in really. Could do
without it but it should fit without causing problems. If the fork was
wrong way round would it foul the rubber then or does it look the same
either way? Can't be much! Keep in touch Cheers Clive
First, If the starter motor runs when the sol is energized, the plunger is
moving all the way. There is a button in the sol that is pushed by the
plunger. This switch is what starts the starter motor running. If you can
move the drive gear all the way to the bushing by hand than there is
something wrong with the fork. You should never be able to move the drive
gear by hand more than a fraction of an inch, maybe .050 in or so.
Check the engagement of the fork and the drive gear.
Paul's Auto Electric
when it come to starters use only good stuff.
i my self would have replaced the whole assembly . but i have the $ to
they ain't cheap but the cheap starters don't last long
the case, minus a few cans!
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