[Vwdiesel] starter issue in Diesel Vanagon

[Bryan Belman]

I guess I should add more.  This is my vanagon camper that I drive often, the engine is not frozen.
When the starter quit 2 weeks back we were on our way to a campout.
We push started the van as needed, no issues when doing this.  We parked strategically as needed.  It was close to home, so we went anyway and had a nice time.
 
The starter place took the starter apart, checked brushes and bearings, NO issues, he said the brushes were like new.  The only thing the guy said was you have a weak solenoid and I should have another one around to swap.  He bench tested it.  I would imagine when I take it out tonight and put it on the bench with extra battery it will work just fine.
 
So, with that said, NOW, what do I do?  Is there any way the Bendix thing is getting jammed and hitting the fly wheel, 
It is my understanding, and I could be wrong, that the solenoid pushes the gear out into the fly wheel and when it is all the way out a contact is made to allow the starter motor to run, take power away from the solenoid and the gear comes back and the starter motor stops running????? yes, no?
 
If somehow the starter teeth are not lining up with the fly wheel teeth this could cause this??  I have never had to do anything but stick these starters in the hole and torque the M12 bolts to 59 ft. lbs as spec says in book for bell housing to engine block.  Turn the key and go, I never had to worry or think about lining up any of the gears, so this is going down the wrong path to fix this issue?
 
thanks in advance.
 
 
 
 

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 :-)

From: "lbaird119 at aol.com" <lbaird119 at aol.com>
To: vwdiesel at vwfans.com 
Sent: Monday, June 11, 2012 12:25 AM
Subject: Re: [Vwdiesel] starter issue in Diesel Vanagon




OK, take the starter out, it is about a 10 year old reman. Bosch and look brand 
ew.  I take it to a starter place for diagnosis.  They say, your solenoid is 
eak and needs replaced, $65 later, I put the starter back in the van tonight.

AME thing, same sound, same issue.

test battery with battery load tester, it is good.  Direct wire from the 
olenoid to the battery + to by-pass the key wire to be sure, same solid clunk 
nd big spark, meaning big resistance from the starter.

hat do I do next?

ake it back out and try to run it on the work bench?  Is there anything in the 
ell housing to could be an isse.
hese vanagon starters do not have a shaft to has to go into a hole or anything, 
hey are pretty much self contained.



  Well yeah it'll still clunk.  The solenoid wasn't bad.  I could tell that from here!  :-)  (Unless the contact was bad, which you check by jumping the two, large terminals together.)  Starter isn't turning.  Either your engine is frozen, the starter motor is frozen.  Could be a REALLY worn bushing in the starter, which you should've heard for a while, a winding or brush is toast, which should be black, stinky or obviously no brush left.  Sounds kind of like the Onan in an Orchard Ape that was run out of oil.  Clunk, and nothing else.  Engine was siezed but they had to spend half a day puling plugs, jumping, etc (probably damaging the starter) to see that I was right.  Hope not in your case but sure sounds plausible.
    Loren

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