The 544 has been sitting for two months waiting for new drums (and time to install). Completed that part, charged the battery and nothing happened. Checked all wires and fuses, everything looked exactly as before when it worked daily without problems. put in a different battery to double check, still nothing. volt meter records a full batter and full 13.5 volts at the starter. the starter does not even click, when the key is held in start position for a while the dash lights dim, and volts drop a little. I was able to push start the car on the first try thinking something got frozen in the starter. let it warm up for 30 minutes. Again it would not start, not even a click. Any suggestions before I invest in a not so cheap new bosch starter?

Thanks.,
-Erik
65 544, 66 220, 66 1800, 68 220 ....not nearly enough time

Starters are simple!
You can fix it!
If not, you can get a used one pretty cheap to use while you learn
to fix the other one.
By all means DON'T get a new one. Prices are outrageous!
If you can't find a good used one locally e-mail me offline.
--
George Downs Bartlesville, Heart of the USA!

Step 1.) HIT IT WITH A BIG STICK
Step 2.) CHECK CABLES.
Step 3.) FOLLOW RON'S INSTRUCTIONS.
Step 4.) REPLACE IT.

Starters aren't complicated at all; a small solenoid of one type or another kicks in when you turn the key (or press the starter button) and this makes a very high amperage connection to the battery, which causes the starter to rotate.

Most cars have the starter solenoid on the starter itself; Ford has a remote solenoid on the fender liner. GM starters have their solenoid on the starter, but they are infamous for their solenoid getting overheated and seizing up until it cools off again. That's why you see so many GM starter solenoid heat shields for sale everywhere!

Regardless of the make of car or the location of the solenoid, you can usually bridge the connectors on the solenoid with a piece of wire to test whether it works or not without having to pull the starter out of the car.

Identify the big cable that goes to the battery, and jump a lead from than connector to the smaller terminal on the solenoid. This should activate the solenoid, which will kick in with an audible 'clunk' and the engine may turn over but not start. Pull the coil lead to the distributor if you're concerned that the engine may start while you are under the car or you have your hands deep inside the engine compartment.

If there's no sound from the solenoid and you're sure you have electricity from the battery, try jumping from the battery lead to the big terminal on the solenoid. This should cause the starter to turn.

If the solendoid doesn't react but the starter turns over, you can replace just the solenoid, although it's usually more trouble than it's worth. If I were having identifiable starter peoblems I'd opt for a rebuilt (and guaranteed) starter.

BUT...I still say that the most common starter problems are caused by bad battery connections.

Good luck!

Steve

Erik;

From your description, it sounds like the solenoid is getting energized (indicated by the dimming dashlights and dropping voltage), but either the solenoid is not pulling in OR the sol is pulling but the high current contacts have a problem, and are not closing, supplying the starter with power...

Sil is on the right track, but if the solenoid work after whacking it, one still doesn't know if it was a problem with the windings or the high current contacts...to determine which is the case, I would recommend shorting the(small) solenoid control wire to the bat terminal to energize it...you should get an audible click and the starter turning over the engine, if you get the click, but little else, keep the control wire energized, and use another test wire to momentarily connect from the bat terminal to the big output terminal (with the wire going down into the smotor)...it the stare moves...then the high current contacts are the problem...

Good Hunting

Check your battery connections, especially the positive cable. Also remove the end attached to the starter and clean it before snugging it down.

I'd run across this problem fairly often when I drove a tow truck; frequently I could get it to start by twisting the starter cable clockwise at the place where it attaches to the starter.

Nearly everyone remembers to clean and tighten the battery ends of the cables; not many think to do the same on the other ends!

Good luck, and keep us posted!

When that sort of thing happens to me my first move is to give the starter solenoid a couple of firm whacks with the end of a broom stick. Sometimes that works, sometimes it doesn't. Try your luck.
Bob S.