Date: Mon, 4 Jul 2011 10:32:25 -0700
Reply-To: Old Volks Home <oldvolkshome@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Old Volks Home <oldvolkshome@GMAIL.COM>
Subject: Re: Starter solenoid: R&R?
In-Reply-To: <1A9677E8-8F3C-4D08-BE0C-64D8A71F7735@telus.net>
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There are two areas of the Bosch solenoid that become problem-prone with age.
1. Piston that activates the Bendix Drive. These are lubed at the
factory with a long-life lubricant. But long-life does not mean
indefinite. The piston needs to be removed from the solenoid bore.
Both piston and bore needs to be thoroughly cleaned and lubricated. I
use the same grease as used on CV Joints. This sounds like what your
problem is. See my link (Item # 5) about this:
http://www.oldvolkshome.com/hardstart.pdf
2. The heavy duty contacts inside the solenoid cap do become corroded
on a Solenoid of that age. The only way to fix this is to literally
destroy the cap off the end of the solenoid, clean the contacts and
reassemble a new cap on the Solenoid. Generally most
do-it-yourselfers don't have the proper tools to do this, but
rebuilders do and some high-end auto electrician's shops do as well.
Removing the Starter is required to perform either procedure above.
I use to sell Bosch Solenoids quite frequently in the 70s and 80s when
their prices were economical enough compared to the price of a rebuilt
starter. But as time went on, the prices of Solenoids for VWs (as
well as Audis and Porsches) climbed into the stratosphere that it
became more economical to purchase a Bosch Rebuilt with a new Solenoid
attached. Most independent rebuilders just do the two procedures
above, essentially reconditioning the solenoid and in many (but not
all) cases works out just fine (I have an independently done starter
on my Westy and on my 914 and both have served me well for the past
several years). Most of the major Bosch WD warehouses no longer carry
Bosch Solenoids because of their high cost and VERY SLOW sales
movement, so finding one can be a chore. But with some searching can
allow you to find one with one Caveat:
About the time VW was moving into Wasserboxers, the Solenoids became a
somewhat permanent part of the starter, making removal extremely
difficult, ie: removing or sealing the attachment screws. In this
case, you're usually left with no choice but to get another starter,
because Bosch/VW did not provide for replacing the solenoid, nor did
they offer a replacement Solenoid. If there are exposed screws, then
removing the solenoid usually required a hand held manual impact tool.
--
Jim Thompson
84 GL 1.9 "Gloria"
84 Westfalia 2.1 "Ole Putt"
72 411 Station Wagon "Pug"
75 914 1.8 "Nancy"
Full Timing Since March 1999
oldvolkshome@gmail.com
http://www.oldvolkshome.com
***********************************
On Mon, Jul 4, 2011 at 8:56 AM, Don Spence <dkspence@telus.net> wrote:
> Trying to get my 83.5 wbx back on the road after sitting for the past
> year plus. Fresh battery but when turning key to start I get
> nothing. I did remove and replace the low amp wore to the solenoid a
> few times, cleaned the grounds etc. After tapping the solenoid with a
> large wrench it did work briefly but has now "gone back into
> retirement".
>
> What is the best/easiest way to remove it? Can it be disassembled and
> cleaned or must I replace it?
>
>
> Thanks in advance
> Cheers
> Don
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