[Vwdiesel] starter issue in Diesel Vanagon

[Bryan Belman]

Just wondering where to go next.
 
2 weekends ago my starter crapped out, just a solid clunk when you hit the key.
 
Not the normal sound or issue you get with a bad ignition switch or bad wire from the switch, old wiring.
I by-passed the key by running a wire from the solenoid flat tab connector to the + on battery with key in the on position on and SAME clunk, strong, but starter motor not engaging.
 
OK, take the starter out, it is about a 10 year old reman. Bosch and look brand new.  I take it to a starter place for diagnosis.  They say, your solenoid is weak and needs replaced, $65 later, I put the starter back in the van tonight.
 
SAME thing, same sound, same issue.
 
I test battery with battery load tester, it is good.  Direct wire from the solenoid to the battery + to by-pass the key wire to be sure, same solid clunk and big spark, meaning big resistance from the starter.
 
What do I do next?
 
Take it back out and try to run it on the work bench?  Is there anything in the bell housing to could be an isse.
These vanagon starters do not have a shaft to has to go into a hole or anything, they are pretty much self contained.
 
 
 

Bryan Belman, Pt. Pleasant, NJ
04 Jetta Wagon TDI PD, 100hp, 5sp -- running :<)
92 Jetta 1.6 Eco-Turbo Diesel, 5sp -- running :<)
82 Diesel Westy 1.9NA -- running :<)
70 Type 1 stock Elm Green Beetle -- Under Restoration :-)