Starter Problem / Testing

[jwalterus]

one thing to check as well, the cable connection to the solenoid from the battery, I had a similar problem up until 2 weeks ago: initial crank was just a click, jump the solenoid across the big terminals so the starter spun, then it'd crank with the key
baffled the heck outta me, turned out the cable had broken inside the crimped area, it was "kind of" held into place (strong enough to take on and off the starter, until I moved it "just right" hooking it back up and it popped out)
spent over an hour going from store to store to find a 4/0 cable end

 

[Zaggnutt]

one thing to check as well, the cable connection to the solenoid from the battery, I had a similar problem up until 2 weeks ago: initial crank was just a click, jump the solenoid across the big terminals so the starter spun, then it'd crank with the key
baffled the heck outta me, turned out the cable had broken inside the crimped area, it was "kind of" held into place (strong enough to take on and off the starter, until I moved it "just right" hooking it back up and it popped out)
spent over an hour going from store to store to find a 4/0 cable end

Will do, thanks. All of my batt cables are crimped and taped. Not soldered properly. I undid the tape, pulled the wire out, cut the old piece of wire off, wire brushed the fitting, stuck wire back in, crimped and taped. Next time I'll use a solder gun but I can't get to mine right now. Long story.

I ended up taking the solenoid housing partially apart too and cleaning some oil out of it as well. Tested it with jumper cables and it engages/spins, but that's all I know for sure. Bought a 3rd bolt to mount it, but it was gettin too cold. Decided to call it a night and get it mounted back up tomorrow. I am going to clean some of the oil out of the flywheel housing area. I am concerned somewhat about dirt damaging the gear teeth moreso than the oil.

 

[Zaggnutt]

Someone dropped/slammed that thing down. See the crack?

It's essentially pinching the inner piece. Can tell because it's a bit worn.


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WHERE?!

 

[Zaggnutt]

Holy Mackerel, I've seen a lot of starters in my life, even used to rewind them, but never anything like that. Hope you polished up the commutator before putting it back together.

No I didn't. I wiped everything down with a clean rag after getting as much of the grime out as possible. I may go over it again tomorrow with compressed air and wipe it down again. Checked bearings for play, but they seemed to be snug and spun freely.

Is there anything else you consider important to check or clean while it's out?

 

[79jasper]

You must be registered for see images attach

Midway down. By the screw.
Is that not a crack?


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[Zaggnutt]

You must be registered for see images attach

Midway down. By the screw.
Is that not a crack?


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Yes, but it's not what you think.... PHEWWWW!!! Don't scare me like that! I may have to use this thing for a while! The housing is metal. The black is a paint or enamel or something. It is flaking and cracking in some spots. I don't know if it is caused by moisture or hot cold cycles. It is on the surface only. Man... good eye!

 

[79jasper]

Oh. Haha
Definitely looked deeper than the paint.


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[Zaggnutt]

Oh. Haha
Definitely looked deeper than the paint.


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Hey, I was just reading your thread on rebuilding your starter... Where's the pics?! Anyway, I have found a ton of info on this, but something I'm unclear about... What is a "bad" brush as opposed to a "good" brush? And also, how much should I be sanding the commutator? Just a light scuff to make it shiny? Thanks.

 

[79jasper]

I did a light scuff and used a pick to clean between.
I need to get the pics off the camera. Lol

I will say something happened with that starter. It would spin just fine, but started getting where it just wouldn't engage. I took it apart, cleaned it, and used a better brand of white lithium grease. Still no better.
I even tried the old solenoid.

I think I may have over greased it. Next time I may use some wheel bearing grease or something.


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[Zaggnutt]

Okay, cool. I appreciate the update...

 

[Zaggnutt]

UPDATE:
Removed housing off of commutator again and lightly sanded copper end... It had a film of grease/oil/dirt. Also noticed some pitting. Lightly sanded copper band the connects brush framework to the black housing. Wiped everything down again. Reassembled.... (you guys weren't kidding on that top PITA starter mounting bolt) Vaseline on the connections to prevent any oil drain damage from leaky vc.

Connected power and....... The starter spins MUCH MUCH FASTER than it has since I bought the truck last Fall. We will see longevity wise. I did not rebuild or replace anything and there is a sticker on the starter that says "reman" in the coding and part description so who knows.

SUMMARY: Because I knew oil was draining onto/into the starter, I removed and cleaned it AS WELL AS wire brushing/repairing batt terminal / ground / starter wiring. Just to help those diagnosing their own problems... I wanted to note a few things.

1. There was a lot of oil residue inside the starter (due to leaking vc).
2. There was a lot of corrosion on the starter solenoid studs.
3. The pass side battery ground cable did not have a clean surface where it was mounted to the block.

Thanks to everyone and their helpful advice.

 

[jwalterus]

the top bolt is much easier to do if you make a "custom" socket for it using a length of rebar welded between 2 sockets

 

[riotwarrior]

the top bolt is much easier to do if you make a "custom" socket for it using a length of rebar welded between 2 sockets

I just use extensions....works for me...Just saying..

Glad it worked out for you.

Did you clean it out with a solvent or brake clean by chance? Or just wipe it down?

Thanks for all the pictures and so forth nice job!

 

[Zaggnutt]

I just use extensions....works for me...Just saying..

Glad it worked out for you.

Did you clean it out with a solvent or brake clean by chance? Or just wipe it down?

Thanks for all the pictures and so forth nice job!

I used a combination of two extensions and a flexible joint to get the right length.

Unfortunately I did not have brakeclean handy and there is just no money for that stuff in the budget. Love it and would have ten cans on hand at all times if possible, but not in the Winter. Anyway, I used a combination of Marine Clean, PB Blaster, and WD. Marine Clean mainly for the casing, PB for the internals and WD to lubricate the mechanicals. Oh, and just about every square inch of a T shirt rag.

I quit my last job to start my own landscape / hardscape / mowing business 2.5 years ago. Bought this truck in the Fall to use for snow removal so that's why I can't afford new starters, rebuild kits, or even brakeclean.... I'm living on snow removal and that's about it so money is tight. My girlfriend has had to convince me that food is more important than parts for the truck... But another reason I jumped ship is because my boss NEVER said thank you, good job, or anything positive. Always "whyju do that?" Shoulda did this" That's not right" etc, etc. Not a bad guy, just a **** for a boss.

Something that never fails to put a smile on my face is when I use one of my old company shirts to wipe off somethin nasty....

Thanks again