912 Electrical Twilight Zone

[driver912]

My 66 had developed an annoying habit of intermittant starting. Over the last few days, I would try to start it , sometimes it would start, sometimes just a click. When it would start, I would turn it off and then try again and only get a click. About 50% of the time, it would start and 50% just a click.

From past experience, I bought a new solenoid just in case. This weekend, checked the battery, 12.5 volts, shorted the starter terminals and the starter would run fine. Shorted out the solenoid and it would click. Short out all three terminals and the engine would start.

OK, so I figure I have an intermittant solenoid. I pulled off the starter and replaced the solenoid, checked its operation while out of the car and everything looked good. Put it back in and only got a click.

Tried over the next day and using the key and also shorting out the extra yellow wire to the regulator, it would only start about 50% of the time.

Then I tried shorting out the terminals on the igition switch and, provided I use a heavy enough guage wire, it would start every time.

OK. I thought, new switch ( I couldn't see how you could get the existing one apart to fix it, it is the kind with the steering column lock on) and even maybe a hot start relay kit.

The battery was run down with all my fooling around and so I put the charger on it.

Now the weird part, the car now tries to start almost every time with the key or the extra yellow wire but won't stay running. When I release the key, or the extra yellow wire, it stops. It's almost like the starter is sticking engaged to the fly wheel. The red and green lights don't come on when the key is in "Run" anymore but both still come on while the key is in the "Start" position. The radio doesn't work anymore!!!!!

I am ready to call in a psychic healer. Did I fry the ignition switch, regulator, starter, generator, everything or just the left side of my brain? Any ideas would be appreciated before I call in Ms. Cleo.

[C. Clark]

Hello,
When I brought my 69, 912 home and started messing with it I also had several voodoo problems. What all of them came down to was grounding. I would clean the main ground on the transmission, take the fuses out, one at a time and gently clean the contact points in the fuse box and the fuses themselves. Make sure the grounds to the body are clean and tight. Older cars are known for this stuff. I hope this helps.
Happy motoring,
Chas.

[craign]

driver,

Your symptoms sound exactly what I experienced a few months ago and it did turn out to be the ignition switch. I did not know that 66's had a steering lock..

On my 69 I was able to get the switch apart and inside I found the contact for the starter with a nice hole burned through it. Getting the switch apart was easy, just a small clip ring on the back that was easy to pop off with 2 small screwdrivers, watch it though that clip can fly quite distance when it pops off.

I bought a switch with no key from Parts Heaven and just swapped internal guts and was able to keep the tumbler and original key.

I don't know if this helps at all with the lock type switch but that is where I would look. One quick test I did to confirm the switch was to put a light tester on the yellow wire and ground then turn the key to see if you are getting power via the ignition switch. I have heard from several other 912 owners that the "hot start" relay is a good thing to do on these as it relieves some of the electrical stress off of the switch and removes the notorious hot start problems.

Craig

[driver912]

Thanks to Scott in Arizona, I put in another ignition switch AND a hot start switch and have had not problems since then. Thanks for all of the replies!

Dawson Locksmiths in the Woodlands knew all about the switch, had it re-keyed and extra keys made in about an hour for around $20.00. I highly recommend them if you are in the Houston area.

I am working with a local machine shop to find a easy way to accurately machine the later front control arm bushings to fit the SWB 912's. I will let you know how it turns out.