Posted by Steve@Advance on May 23, 2019 at 19:36:19 from (66.169.147.211):
In Reply to: Re: Starter trouble posted by Bill in IL on May 23, 2019 at 16:58:14:
A couple things you can do...
First, I would take the starter off, completely disassemble it.
Look for any signs of wear or binding. Look at the spiral grooves where the drive slides on the shaft. Imagine what happens when the fork pushes against the drive. Put it through the motions feeling for any binding. Could be the shaft has some wear, or the inside splines of the drive are worn.
Look at the plunger, does it slide freely into the solenoid? Can you feel it contact the button in the end, and is it pushing the button far enough to make the contacts? A good solenoid can fully seat the plunger even if the gear does not fully engage the flywheel. Theory is, once the contact is made, the drive will turn just enough to go ahead and engage without grinding.
Be thorough in your investigation, don't assume anything without verifying. Take measurements, observe all the motions. There is always a possibility the rebuilders did not do a thorough job, or there was a parts mismatch in the starter from the factory.
If the rear main is leaking, oil inside the starter can cause problems, especially in cold weather. Cold oil makes the plunger hard to pull in. Oily, sticky, worn brushes can mimic solenoid problems, but usually result in a "nothing" situation, no click.
The new solenoid, I'm assuming this is a Delco starter, was it a Delco brand? If not, that could be a problem. Might try finding a factory brand name solenoid over an aftermarket.
And, if all looks good, as others have said, add a primary relay to give full battery voltage to the solenoid. I would use the old Ford fender mount solenoid. Keep the wiring short and heavy, at least #10 or #8, solder on heavy duty ends. The heavy duty solenoid will give better contact than a screw driver across the terminals, so that may do the trick.
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