2nd Gen Non-Engine/Transmission Starter making grinding noise and shooting sparks!

[Coalsmoke]

My starter has been making this grinding noise for a while and I thought it was just sticking on a bit so I got the contact and plunger kit from PDR, but the other day when under my truck fixing an oil leak, my dad noticed that the starter is actually shooting sparks when engaged????



What I'm wondering is if it's been shooting sparks for who knows how long (I've only owned the truck for a few months), then am I going to be better off replacing the whole stupid thing? I can't find any bearing rebuild kits for it. It may be original, and if it is, it will have 205000miles on it.



We're thinking two possibilities of what may be wrong:



1. bearings worn out allowing armature to contact outer shell



2. maybe the brushes have worn down so low that something else like the brush clips are rubbing



It makes one heck of a noise, and we'll be popping it off tomorrow. I did all of the starter searches and found lots of info on replacing starter contacts but NOTHING on shooting sparks. A guy could almost think this isn't a common occurance or something.

 

[crabman]

Starter Fix?

Coalsmoke,

Have you fixed the starter yet? If so, what was wrong and what was the fix??

crabman

 

[Coalsmoke]

almost

Going to pull it apart in about an hour. Scared to look It's probably been doing it for a while. I'll let everyon know the prognosis later. PS, replacements aren't sheap I think I'm going to have to warm up the plastic cash for this one.

 

[redram]

There's not much to go wrong - I had mine apart when I replaced the contacts - also regreased teh reduction gears.....



My guess is the contacts were seriously worn out and how did you get so lucky as to not fry the shut down relay / solenoid, fusible link that normally goes when the starter runs on... ...



Hope it was an easy fix.

External sparks may have been nothing more than a loose connection considering the amount of amperage run thru one of these puppies to turn over the Cummins.

 

[Coalsmoke]

Nope, I was talking sparks coming from the gear reduction nose-piece area. Anyways, I went to tackle the job today, got my tools picked out, got ready to lean into the wrench to try and break the starter bolts loose, and almost fell flat on my nose when I realized that they were loose! All three of them were either loose or barely finger tight. Made for easy removal. Pulled it apart and everything looked fine except for the gear on the actual motor for the starter. It was badly damaged. The teeth were almost cracked off, worn 1/3 away, and pushed over sideways in the direction of rotation more than half the width of the tooth. I'm starting to wonder if the person who had the truck before me drove it by just cranking the starter and not actually having the engine running???? I can't figure out what did that much damage to that one and only one gear. Another thought is that the damaged gear is made to be a "fusible" link, made out of softer material and the starter gears were somehow binding do to not being mounted tight, but that theory doesn't line up too well as it wasn't a case of all the gears (or even the ring gear) being damaged, just that one on the electric motor itself.



I'm open to ideas. Incidentally, the starter looked like it was already replaced and the contacts were almost brand new, hardly any wear at all.