Date:         Sat, 7 Aug 2010 14:34:26 -0400
Reply-To:     Jonathan Poole <jfpoolio@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jonathan Poole <jfpoolio@GMAIL.COM>
Subject:      A starting battery to starter cable replacement story
Content-Type: text/plain; charset=ISO-8859-1

Even after installing a new starter, new starting battery, inspecting and
cleaning all connections and grounds my van still cranked slowly when hot,
if it turned over at all. I put off replacing the battery to starter cable
until last because my cable showed no corrosion or deterioration and because
changing the cable seemed like it would be a difficult task. A few days ago,
after my van wouldn't start in the heat I got motivated and changed the
battery to starter cable which solved my slow cranking issues. Below is my
account of the easy job that may be helpful to some of you contemplating the
change.

After my first stop on my day-trip my van wouldn't restart and I decided
that part of the days recreation needed to go towards fixing my starting
issue. In the next small town I stopped at a tractor dealership in hopes
that they had the cable I needed and the ability to press on the ends etc. I
had to leave my air-cooled Westy idling in the near triple digit heat (thank
goodness for the extra oil-cooler/fan) while the guys inside gave me
directions to a machine shop that could make a new starter cable for me. At
the machine shop they were confident that they could make whatever cable I
needed and also said it would be fine for me to do the work in their parking
lot (that is unfortunately gravel, oh well). Not really knowing what I was
getting into I shut off the van and dove into the cable removal/replacement.
In the end the entire process only took around 30 minutes and cost $35. I
got them to make the cable using wire that was one size larger than the
original that I removed from the van. I believe that they used 1 gauge wire
but I'm sure that folks on this list can make better recommendations on what
to use. The replacement process that I used went as follows:

Disconnect/remove starting battery from beneath the passenger seat.

Disconnect the starting cable from the starter.

Remove the cable from the van moving forward from the starter by removing
zip-ties/and other wire retainers and pulling the starting cable clear of
wires/frame etc. Pay attention to the routing so that the new cable can be
run along the same path.

When the cable is loose up to the hole/passage above the gas tank/next to
the shift rod attach a pull-cord/string to the end that had been connected
to the starter. I used duck tape around the string instead of knots for
this.

Pull the cable up into the batter compartment slowly and smoothly until the
string comes into the battery compartment. Be sure not to pull the string
all the way into the hole above the gas tank.

Disconnect the string from the starter cable and have a new cable made using
the old cable as a guide for length/etc.

Connect your shiny new cable to the string, then pull it back through with
your string until only enough cable is left in the battery compartment for
connection to the battery.

Re-route/install the cable along the old run back to the starter
installing/reinstalling clips and zip ties as needed as you go. Be sure you
follow the same path as the old cable, or that the cable is secure from
hanging down/snagging/chafing etc.

Reconnect the cable to the starter and inspect the wire run making sure that
it is well routed and secured.

Reinstall the starting battery.

Test by starting your van,, if all went well then you are done!


 I felt a bit silly for having put this off for so long once I had
finished.  Throughout the rest of my trip, in high heat, my van cranked and
started quickly every time. Maybe now that my starting system is in such
good repair it is time to get a bigger engine for it??? ha ha.

So, if you are considering this change I say go for it.  Had I known that
these cables were so commonly problematic, and that replacing them was so
easy/cheap, this would have been the first part that I replaced when trying
to fix my slow cranking van.

 Jonathan Poole

'83 AC Westy