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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?
Comments: To: Don Spence <dkspence@telus.net>
In-Reply-To:  <1A9677E8-8F3C-4D08-BE0C-64D8A71F7735@telus.net>
Content-Type: text/plain; charset=ISO-8859-1

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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