Starter Problem?

[frank]

I vaguely recall having this issue before but I don't remember the solution. I also did some searches but came up empty.

I reconnected all my wires after re-installing my motor. Now when I connect the battery the starter starts to whir... even with the key in the off position.

I am pretty sure my starter is correctly wired as per all the diagrams and photo's i researched.

[TheCabinetmaker]

Well you either have a faulty solinoid, or the starter wire has juice on it all the time (faulty key switch ???) see if the yellow wire on the solinoid that goes tothe key switch has positve 12 volts on it or not (without turning the key switch) if you got 12 volts there, then you got an electric problem possibly in the key switch.

you can also remove that yellow wire on the solinoid, and re-hook up the battery, if she still turns, then you know it is a starter solinoid problem, as the yellow wire will no longer come into play.

it is interesting you say the starter whirs, does this mean that the engine is or is not turning with the starter's whirring????

a solinoid that is internally dirty, can jam up, and prevent engagement of the starter's gear, thus allowing the starter to whir, but the engine wont turn. a gummed up solinoid can also stick and cause the soliniod to always be engaged, and thus always turn once the batter is hooked up.


the solinoid can be replaced or repaired, you will need to pull it apart, clean, and remove any rust on the plunger, then put it back together, a very important part of this repair is to seal the solinoids parting surfaces with sealer,. if you do not seal this parting line (seam) then the solinoid will get water in it, resulting in a gummed up /rusty mess inside that will cause the plunger to bind agan. so make darn sure the solinoid is water proofed when you put it back together. this last step of sealing he solinoid seam is often neglected. also use a bit of grease on the plunger to help keep it sliding freely.

[frank]

Interesting comments Cabby,

When I pulled the drive-train I pressure washed the whole thing attempting to avoid the electrical.

I removed the starter and the the solenoid from the starter. I did not notice any gunk as I would have cleaned it just like 99% of the stuff I removed that did have gunk.

The ignition switch is about 2 months old... I did however pull the steering wheel and horn ring to redo some horrible wiring / soldering repair work I did many years ago. Maybe I wiggled something, but I am pretty confident it's not the switch.

The motor is not turning when the starter is whirring.

Maybe I didn't install the solenoid correctly with the plunger incorrectly aligned?

I guess tomorrow I will be removing the starter again and go through your checklist. I think you may be on to something.

I feel like going out to my garage and pulling it now... I hope I talk myself out of it though.

I will make sure to seal the solenoid as you stated before it goes back in.

... I'm going to go disconnect the yellow wire and give it a shot right now. I'm obsessed.

[frank]

Well, I am calling it a night.

I pulled the starter then removed and inspected the solenoid. They both look perfect. No gunk, no rust, no nothing.

I reinstalled them and the issue persists.

I removed the yellow ignition wire and the starter still whirs, even with the key out when I connect the battery.

I connected the battery with the starter disconnected and all other electrical is working fine.

[TheCabinetmaker]

the next step is to pull apart the solinoid, from your post it sounds as if you only removed the solinoid. after it is removed, it can be opened up, then you can see if it is gunked up inside and if the contacts are shorted/burnt, etc... As i recall there are a couple screws on the end of the soliniod that when removed will allow it to be taken apart. the screw heads may be potted with a sealant, which you may have to pick out to gain access to the screw heads. else buy a new solinoid. the soliniod comes apart at the parting line between the plastic section (near the terminals) and the metal body. this metal/plastic seam is one that needs sealing to prevent water from getting in.

[frank]

So last night I removed the starter and separated the solenoid.

The solenoid plunger is sticking out which constantly puts pressure on the starter lever. Is this normal or should the solenoid plunger be recessed until it is energized?

When the lever is pulled toward the solenoid the gear in the starter pops out to turn the flywheel, but how does the lever get pulled when the plunger only pushes? Again, I am not a mechanic so forgive my ignorance. I presume that when the solenoid is energized the plunger is pulled in and allows the lever in the starter to move back.

This does however explain why the starter whirs but does not engage. Only the starter is energized when I connect the battery, so maybe there is something stuck or fused in the solenoid that allows constant power to the starter.

Anyway to test the solenoid? I think I will take it in to my FLAPS and see if they can test it.

[frank]

Cabby,

I did attempt to pull the solenoid apart last night. Something was holding the end with the terminals and I didn't want to break anything.

I was able to pull the plastic section away from the body just barely. I have no idea what is keeping it from separating from the body. I did remove the 2 13mm nuts and the 2 slotted screws but the cap would just not come off.

[frank]

Last night I was working in the dark with a flashlight in my mouth. I noticed this morning that there are two soldered wires that hold the cap on. Before taking the solenoid apart I wanted to get the starter tested. On the machine the starter just whirred and the plunger never came out. I am pretty sure it is a problem with the solenoid.

I decided against rebuilding the unit since a replacement was $37 + tax. No-brainer... already installed and working.

Thanks Cabby for all your input. I have learned about yet another component of my car. Had it not been for the core charge, I would have kept my old starter and rebuilt it but at this point, it's not a project I wanted to take on.

CASE CLOSED.