Author Topic: New Starter Already Fried? (Read 4558 times)

gratefuljoe · « **on:** February 10, 2008, 01:45:55 pm »

Hey All,
Edmonton winter is taking it's toll. I replaced the starter yesterday, in a parking lot, at -26 because I burnt out the previous one with excessive cranking; it was on the way out anyways.

With the new one in, she cranked like a pro and started right up (with the block heater plugged in)

I started her 3 times yesterday, no problem. However, this morning, I went to start her, and she made a *click* noise that sounded like a mix of a metal clacking noise and an electrical ark. After that, the glow plug light wouldn't even come on (or the dome light). I hooked up my battery charger and the glow plug light came back on, and when I turned the key to start, she make a few of those *click* noises before I stopped trying to crank her.

The question is: did I hook the starter up correctly? It's so simple, I really hope I didn't get it wrong: The BIG gauge cable goes from the + terminal on the battery to the top post on the starter solenoid. The medium gauge wire that comes from the alternator also goes on this top terminal. Other than that is just the plastic fitting that fits over the metal spade connection on the back side of the solenoid. All of these were hooked up. Just to give it a shot, I removed the alternator wire and tried cranking, with the same results.

Now, it appears as thought the battery won't hold a charge. The only time I get juice is when I have the charger hooked up. Is there a short somewhere? Help!

Another note: we couldn't get the old copper sleeve out of the slot that the starter shaft fits into, so we just reused it as opposed to the new one. Could this have done any damage?

Thanks,

gratefuljoe

BigVWman · « **Reply #1 on:** February 10, 2008, 02:48:52 pm »

I think i would be double checking ground connections and other elec connections. Maybe check your voltage at battery posts and see if ITS really dead when you have the issue or is voltage dropping out somewhere along the line!

jtanguay · « **Reply #2 on:** February 10, 2008, 03:10:52 pm »

sounds to me like you just need a new battery... don't forget to clean contacts/ground connections too...

easy test.. get someone with a good battery to boost you. if it boosts then you know what to do. these engines take quite a bit of juice to start up... i remember some people trying to boost me with crap batteries.. thing wouldn't even turn over :lol:

Vincent Waldon · « **Reply #3 on:** February 10, 2008, 08:47:42 pm »

1) I'd do the starter bushing for sure... especially if the old one got damaged in an attempt to take it out. :wink: Bosch isn't kidding about the warranty.

2) you may in fact have a battery issue... you have good grounds (at least the last time I checked !) and you've wired up the starter correctly. However, a jammed starter will drain a battery flat very very quickly... so it's a little hard to tell.

Once you get it running, Rockys and other such places will test your entire battery system for free (at least they used to !) .. a load test on the battery, one on the alternator, etc... if it's still fighting you when you finish the bushing perhaps that would be the quickest way to narrow it down, although heaven knows what their wait time is at the moment. +2C by Friday !!

Vince

rabbitman · « **Reply #4 on:** February 11, 2008, 12:54:27 am »

Mine does that "click" thing to sometimes, and the dome light, dash lights and glow plugs all quit working, I just wiggle and tighten the battery connections and it usually fixes it first try.

Op-Ivy · « **Reply #5 on:** February 11, 2008, 01:31:10 am »

Quote from: "rabbitman"

Mine does that "click" thing to sometimes, and the dome light, dash lights and glow plugs all quit working, I just wiggle and tighten the battery connections and it usually fixes it first try.

Same. As Vince said, these engines do need a lot of juice to get cranking. I think if it's really cold out it may just be too much for the battery. However, if wiggling the connection to the starter fixes the problem, (at least temporarily) it may be a good idea to look into getting new connections. I think i probably will come spring.

Matt

gratefuljoe · « **Reply #6 on:** February 11, 2008, 02:12:21 pm »

Vince strikes again...

It was the bushing. I pulled the starter and used Vince's excellent instructions:

http://vincewaldon.com/index.php?option=com_content&task=view&id=29&Itemid=28

The tap was the perfect tool to extract the old bushing, which we had badly deformed trying to get out the first time. I meticulously cleaned the whole area. Then we lightly greased the new bushing, put it in and put everything back together.

It has worked like a charm ever since. So, to all those that would seek to speed their starter replacement procedure, definitely get the tap and take out the old seal.

I have no idea what caused the battery to lose it's juice like that. I cleaned a bunch of the connections and re-crimped the wire from the alternator back to the starter.

By the way, this new starter is unbelievable. 1/2 crank is all it takes. Wow.

Thanks Guys, again and again and again.

-Gratefuljoe