Rebuilding Vanagon Starter
Posted: Fri Nov 10, 2006 12:49 am
My starter packed it in a few days ago. Lucky it was in the mountains and I was on a hill. I drove back to Montreal, parked it, opened up the starter and was horrified. The starter died once before too but it was only hours (driving hours) after the td engine swap. That death is understandable since the starter was old and had to crank a bigger motor. I caught a flatbed truck from the main highway thanks to the police within 10 minutes. I ended up at the driver's garage. He was good and efficacious and found a re-builder for the starter. So I get handed this sparkling starter over the counter, recognize it as mine and ask what was wrong with it? He says brushes and solenoid changed for Bosch parts... all Bosch.
It is not easy but do not trust this starter rebuilding work to anybody but the most intrepid shop. I looked at all the Bosch parts in my starter and found them to be all-original including the brushes. The brushes and Com. are in good shape mind you. But the grease on the drive and shaft is thick, full of grit and sticky. That starter I just overhauled was "rebuilt" by a place in Riviere de Loup (wolf river) that "specialized" in starters and alternators. Not to sound too biter but they were/ are cons..... charged way too much money and didn't do anything but put grease throughout the starter.... not a new solenoid not even new brushes. Do it yourself. Please
IMHO these Bosch starters do not need any grease. There are brass bushings for all the main axle bearing points so the most you can do is clean all surfaces well (no grease), apply graphite powder liberally and put it back together clean.
I bought a new Brazilian solenoid for $23 cleaned free of oil and dressed with graphite. Bosch was $80+ and would take weeks. Also need was real Bosch Torx bolts for the solenoid to replace the crappy Phillips that nearly mangled before coming out (torch, impact, hammer.)
The shaft of the starter was jammed by particle imbedded grease... and very difficult to move by hand even. I cleaned the whole thing with carb.. cleaner and a toothbrush.... paying special attention to the spiral splines.
Btw don't get carb cleaner in your starter drive... it kills it. Out of ignorance I used the spray carb cleaner and scrapped the weirdo clutch/ gear thing on the sliding drive shaft. I hooked up my new starter after testing it on my bench (plywood on dinner table) and it sounded like motor missing a bearing (and no cranking of engine.) Once the motor screaming and my cursing quieted down I called a friend about it. He says it's the drive and so I will change that tomorrow. In the mean time I want to share my overhaul pictures with you.
http://photos1.blogger.com/blogger/3322 ... oils.0.jpg
Cutting the coil contact to change old wires on both the supply to the coil and the lead from the coil to the brushes.
http://photos1.blogger.com/blogger/3322 ... rimp.0.jpg
I used crimps and silver solder incase it ever gets hot enough to melt the metal.
http://photos1.blogger.com/blogger/3322 ... iron.0.jpg
Big ass 300w iron thanks to Keith.
http://photos1.blogger.com/blogger/3322 ... eads.0.jpg
New connections with crimps covered with shrink tube.
http://photos1.blogger.com/blogger/3322 ... G_3984.jpg
Also crucial is that the ground for the brushes must be new metal. So the cap at the brush end should be cleaned from rust, screws, washers and body too. Check for end play, clean and lube with graphite.
New solenoid and soon new drive.
It is not easy but do not trust this starter rebuilding work to anybody but the most intrepid shop. I looked at all the Bosch parts in my starter and found them to be all-original including the brushes. The brushes and Com. are in good shape mind you. But the grease on the drive and shaft is thick, full of grit and sticky. That starter I just overhauled was "rebuilt" by a place in Riviere de Loup (wolf river) that "specialized" in starters and alternators. Not to sound too biter but they were/ are cons..... charged way too much money and didn't do anything but put grease throughout the starter.... not a new solenoid not even new brushes. Do it yourself. Please
IMHO these Bosch starters do not need any grease. There are brass bushings for all the main axle bearing points so the most you can do is clean all surfaces well (no grease), apply graphite powder liberally and put it back together clean.
I bought a new Brazilian solenoid for $23 cleaned free of oil and dressed with graphite. Bosch was $80+ and would take weeks. Also need was real Bosch Torx bolts for the solenoid to replace the crappy Phillips that nearly mangled before coming out (torch, impact, hammer.)
The shaft of the starter was jammed by particle imbedded grease... and very difficult to move by hand even. I cleaned the whole thing with carb.. cleaner and a toothbrush.... paying special attention to the spiral splines.
Btw don't get carb cleaner in your starter drive... it kills it. Out of ignorance I used the spray carb cleaner and scrapped the weirdo clutch/ gear thing on the sliding drive shaft. I hooked up my new starter after testing it on my bench (plywood on dinner table) and it sounded like motor missing a bearing (and no cranking of engine.) Once the motor screaming and my cursing quieted down I called a friend about it. He says it's the drive and so I will change that tomorrow. In the mean time I want to share my overhaul pictures with you.
http://photos1.blogger.com/blogger/3322 ... oils.0.jpg
Cutting the coil contact to change old wires on both the supply to the coil and the lead from the coil to the brushes.
http://photos1.blogger.com/blogger/3322 ... rimp.0.jpg
I used crimps and silver solder incase it ever gets hot enough to melt the metal.
http://photos1.blogger.com/blogger/3322 ... iron.0.jpg
Big ass 300w iron thanks to Keith.
http://photos1.blogger.com/blogger/3322 ... eads.0.jpg
New connections with crimps covered with shrink tube.
http://photos1.blogger.com/blogger/3322 ... G_3984.jpg
Also crucial is that the ground for the brushes must be new metal. So the cap at the brush end should be cleaned from rust, screws, washers and body too. Check for end play, clean and lube with graphite.
New solenoid and soon new drive.