Starter solenoid rebuild-sometimes things just go bad to worse!

[secondchance]

Symptom: Starter wouldn’t turn when heat soaked and yet you can see the volt gauge drop due to current flow.

This starter was installed in Fall of 2012 and logged about 50,000 miles.

Rather than spending $200 on a new starter, I thought I would give a shot at rebuilding the solenoid. Sounds easy enough. Right?

Once again, the plenum comes off, plug wires disconnected, ignition coils and the coil tray removed and pulled the starter. So far, I have about one hour into this.

3 bolts removed from the solenoid plunger cover, cover popped off revealing the plunger and contact plates.
http://i658.photobucket.com/albums/uu303/byongyun/IMG_0349%201_zpsw0asfegf.jpg (http://s658.photobucket.com/user/byongyun/media/IMG_0349%201_zpsw0asfegf.jpg.html)
Replaced both contacts and ready for reassembly.
http://i658.photobucket.com/albums/uu303/byongyun/IMG_0351_zps568gnlbg.jpg (http://s658.photobucket.com/user/byongyun/media/IMG_0351_zps568gnlbg.jpg.html)



Old contact plates were worn down where the plunger had made contact. Interesting to note that one side wore more than the other side.

Got everything back together, intake plenum lined up, plenum bolts in. Looking for my torque wrench, I see two starter solenoid plungers - oneold and one new. Noooooo! I removed the plunger to take a pic showing two newcontact plates and must have forgotten to reinstall the plunger before closing it up… S**t!!!

So, I go through top end disassembly all over again, pull the starter, remove solenoid cover, install the plunger, the cover, back in the valley followed by coil base.

10 mm head bolt (M6?) to fasten ignition coil base, passenger side back, I had the bolt double side taped to a socket with u-joint to start threading. As I am bring the contraption to line up, the bolt drops right above the intake runners. I had all runners plugged with paper towels when I did this the first time. Second time around, with all the frustration of having to do the same again, I over looked closing off the injector housing openings. Now I am not sure whether the bolt went into the intake or dropped in the engine V. Out of frustration I call Jagdpanzer to consult. ‘Course, calm and collected Phil tells me to get a pencil magnet and fish all the IH intakes.


I drive out to Advance Auto Parts, buy a couple of magnets on bendable goosenecks. As I am going through each intakes I get to cylinder #3, secondaryintake, I hear that “click” as the magnet gets hold of the missing bolt! Whew!!!

Another hour and a half and finally everything is buttoned up. Sure was a day of hell!

Hopefully, solenoid rebuild has fixed periodic non-start issue.

[conesare2seconds]

Sounds like one of my projects, haha. Glad you got the bolt back and everything worked out. I may be doing this service soon myself.

[Roadster]

Wow, and sometimes I think I have complications.......
Glad everything worked out....
Now the big question.....does the engine start???
Lol, couldn't help myself......:D

[BigJohn]

Wow, and sometimes I think I have complications.......
Glad everything worked out....
Now the big question.....does the engine start???
Lol, couldn't help myself......:D



Mine does!!!

:cheers:

[QB93Z]

Perseverance pays off.


Well done.


Jim

[Paul Workman]

So, now I'll ask: You didn't happen to see if the length of the plungers were the same, didja?

Depending on where you got the new one, it may NOT BE SO! I ended up reusing my old one - choosing to referbish instead of replacing it due to the difference: would have resulted in the pinion only engaging about half of the FW ring gear if the new one was used!!

Sweet dreams, buddy! :cheers:

[Dynomite]

Once again, the plenum comes off, plug wires disconnected, ignition coils and the coil tray removed and pulled the starter. So far, I have about one hour into this. 3 bolts removed from the solenoid plunger cover, cover popped off revealing the plunger and contact plates Got everything back together, intake plenum lined up, plenum bolts in. Looking for my torque wrench, I see two starter solenoid plungers - one old and one new. Noooooo!

I removed the plunger to take a pic showing two newcontact plates and must have forgotten to reinstall the plunger before closing it up… S**t!!!

So, I go through top end disassembly all over again, pull the starter, remove solenoid cover, install the plunger, the cover, back in the valley followed by coil base. 10 mm head bolt (M6?) to fasten ignition coil base, passenger side back, I had the bolt double side taped to a socket with u-joint to start threading. As I am bring the contraption to line up, the bolt drops right above the intake runners. I had all runners plugged with paper towels when I did this the first time. Second time around, with all the frustration of having to do the same again, I over looked closing off the injector housing openings. Now I am not sure whether the bolt went into the intake or dropped in the engine V.

Out of frustration I call Jagdpanzer to consult. ‘Course, calm and collected Phil tells me to get a pencil magnet and fish all the IH intakes.

I drive out to Advance Auto Parts, buy a couple of magnets on bendable goosenecks. As I am going through each intakes I get to cylinder #3, secondaryintake, I hear that “click” as the magnet gets hold of the missing bolt! Whew!!! Another hour and a half and finally everything is buttoned up. Sure was a day of hell! Hopefully, solenoid rebuild has fixed periodic non-start issue.

Been there and done that.......happens to all of us who decide to DO IT OURSELVES :handshak::thumbsup::thumbsup:

[secondchance]

So, now I'll ask: You didn't happen to see if the length of the plungers were the same, didja?

Yes I did. It was after checking the length, I forgot to reinstall in the starter.

[Paul Workman]

Yes I did. It was after checking the length, I forgot to reinstall in the starter.

Oh, good! (whew!) Dodged THAT bullet at least!:-D

[secondchance]

Been there and done that.......happens to all of us who decide to DO IT OUTSELVES :handshak::thumbsup::thumbsup:

I guess you are right. Besides, I know it was done right. No bolts or nuts under the starter and neat and clean as it should be.:cheers:

[Ccmano]

Don't feel bad, we all do things like that. A couple weeks ago I changed the fuel pumps on the Z. Got it all buttoned up, turned around, and laying on my work bench were the strainers that attach to the bottom of the pumps! Sh!t... I was so impressed at how quickly I could pull the pumps and replace them I left the strainers off. Had to pull everything apart again. Oh well.
:cheers:
H

[BlackZR1]

Yes I did. It was after checking the length, I forgot to reinstall in the starter.

secondchance, do you have a source/part # for the plunger? I've looked far and wide for the correct length plunger but had to settle for cleaning up the old one like Paul did.

Thanks,
Roger

[secondchance]

secondchance, do you have a source/part # for the plunger? I've looked far and wide for the correct length plunger but had to settle for cleaning up the old one like Paul did.

Thanks,
Roger

http://www.nationsautoelectric.com/densoparts.html

Call Nations Auto Electric. They actually have a real tech on the other side who will go through the book, figure out LT5 specific starter and identify plunger and contacts.

http://i658.photobucket.com/albums/uu303/byongyun/IMG_0351_zps568gnlbg.jpg (http://s658.photobucket.com/user/byongyun/media/IMG_0351_zps568gnlbg.jpg.html)

OEM starter had smaller contacts on both sides. The kit came with one smaller contact plate and assortment of contact plates with elongated ears (?). I picked one that worked geometrically. OEM contact plate on one side had worn down noticeably more than the other side. I used elongated plate on the side with excessive wear figuring more meat will reduce the relative wear resulting in even wear on both sides.
If you want smaller plates on bothe sides like the OEM, just make sure they send you two smaller contact plates.

I think I will try rebuilding an alternator next time.

[HAWAIIZR-1]

Glad to hear all is well in the end Yun! I have had more than my share of similar situations so I'm there with you on this.

[ssrszz4]

Yes just sounds like a normal day at the office!

Sent from my XT1585 using ZR-1 Net Registry mobile app (http://r.tapatalk.com/byo?rid=90383)

[secondchance]

Thanks guys for words of encouragement.
First heat soak test, 15 minutes after shut down, was a success! Hope I didn't jinx myself...

[BlackZR1]

http://www.nationsautoelectric.com/densoparts.html

Call Nations Auto Electric. They actually have a real tech on the other side who will go through the book, figure out LT5 specific starter and identify plunger and contacts.





Thanks Yun I'll check them out.


Roger

[BlackZR1]

Here is the Plunger Part # for anyone looking for the correct part. Purchased from Nations Starter & Alternator (thanks Yun)

Denso 053660-7061
$21.95 + $8 shipping
I checked every dimension against the plunger in my new spare starter and they all check out, especially the 100.5mm overall length.

[FU]

Denso 053660-7061 $ 13.76 shipped on here.

https://www.finditparts.com/products/2378887/denso-053660-7061

[Paul Workman]

As I rest my left foot on one of the original heads from my ZR-1, all I gotta say is...IT COULDA BEEN WORSE! LOL!

[secondchance]

As I rest my left foot on one of the original heads from my ZR-1, all I gotta say is...IT COULDA BEEN WORSE! LOL!

Now, it's all forgotten. Sorta like giving birth?

Those who intend to recondition starter solenoid - don't forget to get contacts. Contact plates wear out and should be replaced.

[Ccmano]

Old thread, I know... what’s a good source for the contacts?
Thx
H
:cheers:

[secondchance]

I got contacts from Nations Auto Electric.
http://www.nationsautoelectric.com/densoparts.html

Call them up. They have real sales staff with technical knowledge.

[DRM500RUBYZR-1]

Yet another example of why this organization and more importantly it's members are priceless!
:cheers: :cheers: :cheers:
Marty