Date:         Mon, 25 May 1998 14:05:49 -0300
Reply-To:     Tim Smith <smitht@UNB.CA>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Tim Smith <smitht@UNB.CA>
Subject:      <syncro> starter differences
Comments: To: CanineWolf <CanineWolf@AOL.COM>
Comments: cc: vanagon@vanagon.com
Content-Type: text/plain; charset="us-ascii"

Hi,

Syncro starter is same BUT the solenoid is different!!  Enough that a 2WD
one WILL NOT FIT!  Problem is that Syncro has very heavy cabling to starter
and the 'terminal' that goes onto the starter is about 1/2" thick, not a
cheapo crimp on type eye-lug like the 2WD.  The main post on the solenoid
need to be about 1/2" longer than normal, and although extensions are
avaialble to bolt on, they are for repair of sheared posts, and are actually
no longer once on. So don't buy the line that they are the same as 2WD.

The fix.   Since I hate the idea of being stranded due to Syncro-nisity, I
carefully sawed the Syncro terminal down by half, and filed smooth/flat.
Still ample area to carry the current, now fits onto the regular 2WD
solenoid, but the rubber boot needs a tie-wrap to keep it snug. Have fun
fighting the gas tank when you swap this!

Another fix....  My spare battery under drivers seat was a homebrew install.
It's  '+' wired into the main battery by some #8 or 10 gauge wiring, enough
for about 30amps charging current, but will not stand starting current.
Wiring is protected by both an inline 30amp fuse and a relay that is only on
when ignition is on/not at start (use headlight terminal at fusebox).
BUT... the cheap fix was that a longer than needed 'real' ground cable was
used, along with the positive wiring.  This way I can put any battery that I
find (within limits) in there and wire up. Then if stuck with shot main
battery, any spare will do, I connect the + terminals with a booster cable
for starting under those situations.

This kind of bulletproofing was one reason behind going to 15" rims, to get
commonly available tires in any neck of the woods.

bye, Tim