Starter solenoid rebuild hint

[KStretch55]

Hey, here's something I learned last night. I've been having intermittant starter problems with my '92 Loyale AT wagon. Usually seems to happen when one of my daughters is driving and I don't like the thought of them stranded somewhere. I read on here a while back that the solenoid contacts get dirty and stuff. So, a while back I tore it open and found the contacts very pitted and worn. What I thought was unusual was one of the side contacts was worn about 1/2 way through, while the other was just slightly worn. I cleaned up both side contacts and the ring contact with some emory cloth and put it back together. Worked good, didn't have any problem.... for about 6 weeks. It did it again last Sunday and Monday. So, Tuesday I picked up a rebuild kit at Schucks (13.99). It includes a new solenoid plunger w/ ring contact and new side contacts. Installation was pretty simple, except I still had the problem when I put the starter back in. I pulled it back out and took a look at the contacts. I found that they were only making contact at the very side tip of the side contacts. When you torque the bolt that holds them down, you tweak the contact to the side too. So, I took a drift and small hammer and tapped them on the upper corner enough so they looked more level. Then I put a light coat of talcum powder on the ring contact and pushed the plunger in so the ring contacted the side contacts pulled it back out. The talc left on the side contacts gave me a good indication that I had good contact across much more of the surface now. I wiped all the talc out and reassembled the starter and installed it. So far, it works like new

[Cougar]

Well done. You won't have to look at those contacts ever again I would think.

[KStretch55]

Damn! I still have the intermittant problem. Now, I'm thinking the bearings or the brush blocks in the starter may be worn. Does anyone know if the two small phillips screws in the motor endcap just hold the motor brush assy to the endcap? If nobody knows, I guess I'll find out this evening.

[Ross]

I had a similar problem. The shaft on the end of the starter on which the gear slides on had become so dry and crappy that the solenoid no longer had the strength to move it. I took it apart and oiled it up, now it works fine. (Apart from a few other problems....)