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Discussion Starter #21
Well, i'm 99 and 44/100% sure I have to pull the starter and just about to start but thought I would pose some questions in case I am missing something;
Yesterday, heard the "clunk" sound around 12 times then starter caught.
Warmed her up, started again and again and then again "clunk". Opened up both of the large connectors to clean the contacts. After that, nothing...not even a "clunk". So, opened up again, moistened the pins (with spit) and started. Went for a drive and after being parked for about 10 minutes, just the "clunk" for b about 10 attempts, moistened contacts....clunk around 4 times then caught.
I don't believe it is a weak battery. I would be surprised if it was a ground issue.
I don't have a wiring diagram and don't know if multiple dirty pins would cause this issue (Pin 1 for power, another pin for signal to ???)
I expect it is a failing commmutator in the starter. Brush kit is new. Solenoid is new. I am wondering if the new brushes are snagging against a rough part of the commutator and adding too much friction, simply not sitting properly (again, uneven commutator contacts) or if I simply misunderstand how this thing works.
Would hate to pull it if it was something else and am getting tirefd of looking at a non-driveable car.
 

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Why not just bite the bullet and pull the starter? Strip it down and rebuilt it, and the solenoid.
When my cambelt jumped a few teeth I tried everything else, denying to myself it could be a cambelt jump causing rough running, just to avoid going there. The cambelt had jumped and discovered why when I saw a hole punched through the middle of the belt. A bolt I had dropped into the V the day before had not stayed in the V but had made its way to where it was least wanted. I was grateful the belt hadn't snapped and, 12 years on, here we are...
It is a horrible job with the starter but easier the second time round and sorting it will save you all this endless hassle.
 

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Discussion Starter #23
I did start last evening. Pulled the 6 manifold nuts and am removing the rest this morning with the home that I can squeeze in a trip to the starter shop. Funny thing is that the starter worked fine before the rebuild, albeit a bit slower turning. I only replaced brushes as I was about 1/4 of the way there anyways when replacing some exhaust gaskets. if it aint broke.....
 

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Did you turn the armature on the lathe and check for open/shorted segments afterwards?
 

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Discussion Starter #25
Nope. I don't have a lathe.I have taken the starter out and will visit the starter guy this morning...time permitting. Thanks for advice.
 

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Good luck with it. Will be interesting to see what they say. I paid a specialist £90 to rebuild mine when it went. Money very well spent - has been perfect ever since.
 

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Discussion Starter #27
Went to the starter shop yesterday. Starter guy cleaned up the armature and gave me 2 brass bushings. As the rear bushing is staked in, I had decided to just order a rebuilt if he had one available. He did; a $199 quote plus core.
So, I put my old solenoid back on to the starter, as that solenoid was new, stopped by today to swap the units. Turns out the rebuilt one is wrong....only 2 mounting holes, different neck and gear placement. So, back to the books and with no success to be found (the cross reference number pointed to the Delco unit he had ordered)and barring any new defects to be found, he will be rebuilding mine and putting a new solenoid on. He believes the solenoid was the issue. Maybe yes...I hope yes. The starter worked prior to my overhaul and solenoid swap. That was done as a precaution as I had taken the manifold off for new gaskets. The old brushes were at about 50%. The rebuilt spun up much, much more quickly so probably a good idea. It may be that a funky "new" solenoid was the issue. Time will tell.
I think I will paint the exhaust manifold... basic heat-proof black as no one sees the rear one. The front, maybe red to match the revised plumbing.
 
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