Starter solenoid woes

[Phil Stuart]

My starter is acting up again. Today when I came out of the Sheetz store , I turned the key to start her and all I heard was a clicking noise (the starter relay pulling in). With the help of a large pair of pliers to hit the solenoid and a bystander to turn the key over,she finally started.

This is the third time it has happened. I had replaced the contacts and plunger with Larry B's super size contacts about 1 1/2 year ago and has started fine ever since. Now this episode of the solenoid sticking.

I did a forum search and found a possibility it could be worn brushes?correct me if I am wrong,but the starter motor brushes shouldn't have anything to do with the solenoid not pulling in, right? The brushes are just for the motor itself. Is there any possibility the solenoid could be weak and not have the pull it used to?I did remove the starter a week ago and cleaned the plunger and spring and the little ball that sits in that hole. Worked good for a week and now it's sticking again.

I priced new starters ,and I can say it's no chump change

Appreciate any help folks.



Phil S

 

[blacksheepdiesel]

Phil,

Had the same symptoms on my '89. I would take the starter off the truck and use jumpers cables on it and it worked perfect. Put it back on the truck and nothing. Replaced the contacts. Still nothing. After getting tired of taking the starter off & on I put new brushes in it and WHAM!, fixed the problem. Brushes are very inexpensive.

Go for it!

Godspeed,
Trent

 

[Phil Stuart]

Trent,

appreciate the reply, but am curious how the brushes affect the solenoid operation. If the brushes indeed have an affect on the sticking solenoid then I'll buy the plate with brushes already on them from Larry B's.

I've got no idea if it's the original starter or not, truck has 293,000 miles on the odo.



Phil S

 

[blacksheepdiesel]

Phil,

Don't know the answer, it just does. If I were to guess I would say maybe the ground comes through the brushes before it gets to the solenoid??? Might ask Larry B

Godspeed,
Trent

 

[Phil Stuart]

Just got off the phone with Larry B and he said it could be the clutch assy. is worn and/or dried out not allowing the solenoid plunger to move freely in the bore , and most likely the brushes are shot too. He also said that if in fact it is the original starter, 293,000 miles is a good lifespan.

Does anyone know who sells REMAN. units? just curious. All Larry B sells is new. I've got to think on this one.



Phil S

 

[blacksheepdiesel]

Phil,

Larry knows these starters real well. I only know what my experience was. The solenoid would click but the brushes were not making contact with the armature so it could not turn over.

If you are somewhat mechanically inclined (which seems to be the case) pull the starter off and tear it down to where the brushes can be inspected. Take it to a local reputable rebuilder and ask their opinion. My bet is for less than $20 bucks of brushes it wil be fixed. If it is not repairable then you have good solid info for making a decision.

Godspeed,
Trent

 

[Phil Stuart]

Trent,

Larry B also said the difference between the 89-93 and 94-02 brushes is the earlier ones are larger, therefore the brushplate listed for the later models will not fit I just may tear it down and have a peek at the brushes. Wouldn't surprise me if they were shot.



Phil S

 

[jrjuday]

Phil; have you checked the starter relay on the driver side inner fender? It can cause the same symptoms.

 

[Phil Stuart]

jr,



The relay is working good, I can hear it pulling in when I turn the key to start. It's just the solenoid sticking and not pulling down.

I did tear into it today and I must say it is quite a beefy unit!

The brushes were definitely shot Trent, and seems like two of them wore more than the other two. But nonetheless all four worn out.

There was so much carbon dust it was a black cloud when I blew it out with compressed air I will also clean and lightly grease the worm and other gears in the drive end with Lubriplate.

Good news is I found a gentleman who lives but 20 miles from me who runs a starter rebuilding business. He said he has the brushes I need (there were two part #'s). Must be 'cause the later models are not as large.

I'll pick them up sometime next week.

If this fixes it I will definitely be saving some cabbage!



Phil S

 

[bgilbert]

Many new and or reman starters have been purchased over the years for big money when all that is needed is a set of brushes for less than $20. I have two HIGH mileage trucks like yours and both received a new set of brushes, contacts and plungers and they're like new now.



For the rest of you guys with trucks of high mileage say between 100k and up, this is a job best done NOW, before it's 2* with a windchill of -10* and you have to pull your starter outdoors.

 

[Phil Stuart]

For the rest of you guys with trucks of high mileage say between 100k and up, this is a job best done NOW, before it's 2* with a windchill of -10* and you have to pull your starter outdoors.

Amen to that Bill!



Phil S