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stigomery

Member Since: 10 May 2016
Location: Cambridge
Posts: 277

Overhauling the starter solenoid

My starter solenoid is on the way out and I have a service kit ready to deploy. I was going to do it at the weekend and had assumed I could probably do it in-stiu, in fact I'm sure I've read instructions on doing so somewhere but cannot find them.

Once I had the front wheels up on ramps it became clear it was a lot tighter in there than I thought.

Having read that getting the starter motor off can be a real ball ache is it possible/wise to do in situ or should I dedicate a day (yes, I might be that inept) to getting the starter off and doing in on my workbench?

21st Aug 2017 10:14am

miker

Member Since: 13 Sep 2015
Location: Surrey
Posts: 1763

I'd take it off personally, removing the top bolt is the difficult one, if you can source an assistant it gets much easier!

My method is to have a person underneath with a ratchet and a long extension, and the other person reaches in from the top to guide the socket onto the bolt.

21st Aug 2017 10:37am

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

15mm socket 6 point type ^

21st Aug 2017 12:35pm

MadTom

Member Since: 10 Sep 2013
Location: Olomouc
Posts: 622

Removing the starter is a bit hard, because of the top nut. Replacing the solenoid internals with starter still in car is possible, but it is a bit blind-work. I have done it once on Discovery2, after 1 hour long fight with the top bolt. Some years later, we had to remove a lot of parts from engine to remove the top bolt. And we found, that some used some thread locking glue on the nut.

3/8" 15mm nut is the key tool. "Drobek" = The Small One - Discovery 2, "BlufÃnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo

21st Aug 2017 1:22pm

stigomery

Member Since: 10 May 2016
Location: Cambridge
Posts: 277

Cheers chaps

Does it require a flexi/UJ extension bar or will a simple straight extension do the trick on a 3/8" ratchet?

21st Aug 2017 1:34pm

MadTom

Member Since: 10 Sep 2013
Location: Olomouc
Posts: 622

Flat ratchet and extension with the right length. No need for any flex.
I have bought 1/4" 15mm nut and it is even easier, but 15mm is not easy to buy in 1/4" size. "Drobek" = The Small One - Discovery 2, "BlufÃnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo

21st Aug 2017 6:24pm

Dave T

Member Since: 07 Jun 2013
Location: Glasgow
Posts: 490

I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last 2015 RRS Autobiography SDV6
1994 Def 90 300tdi

22nd Aug 2017 6:12am

MadTom

Member Since: 10 Sep 2013
Location: Olomouc
Posts: 622

I have better experience - during last 5 years I have made quite a few of these solenoid repairs, without any return. 50/50 I made also at least clean and re-grease of the starter gearbox. 50/50 only, because on half of them the screws were so tight, that I let it be, rather then breaking them. "Drobek" = The Small One - Discovery 2, "BlufÃnek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo

22nd Aug 2017 6:19am

stigomery

Member Since: 10 May 2016
Location: Cambridge
Posts: 277

Dave T wrote:
I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last

Really? Starter motors for the Td5 are around 150 quid, the repair kit is 14 quid. My starter motor was replaced in 2013 so i would expect a lot more life out of the unit itself than 4 years. It's just a sticky solenoid and a tap with a lump of wood frees it when it happens (twice in the last 12 months)... for now a repair will do me...

22nd Aug 2017 6:58am

Screbble

Member Since: 26 Apr 2015
Location: Lancashire
Posts: 2102

2004 Defender 90 Td5 XS CSW Zambezi Silver

Might help

http://www.defender2.net/forum/topic43925-30.html

22nd Aug 2017 8:55pm

Dave T

Member Since: 07 Jun 2013
Location: Glasgow
Posts: 490

stigomery wrote:
Dave T wrote:
I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last

Really? Starter motors for the Td5 are around 150 quid, the repair kit is 14 quid. My starter motor was replaced in 2013 so i would expect a lot more life out of the unit itself than 4 years. It's just a sticky solenoid and a tap with a lump of wood frees it when it happens (twice in the last 12 months)... for now a repair will do me...

May be different, but the only solenoids I could find were £30, where did you get one from? I got a starter from here, has been really good

https://www.directautoelectrical.co.uk/par...amp;cat=12 2015 RRS Autobiography SDV6
1994 Def 90 300tdi

23rd Aug 2017 5:41am

stigomery

Member Since: 10 May 2016
Location: Cambridge
Posts: 277

Linky:

X8R

23rd Aug 2017 8:00am

rsms

Member Since: 12 Jan 2013
Location: Home
Posts: 36

Starter motor gears grease

Hello,

I am in a process of replacing starter solenoid in my TD5 and this would be the right time to re-grease the gearing part of a starter.

Looking for some advice on what grease would be suitable for inside gears /shaft?

Thanks!

25th Apr 2024 12:53pm

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