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I replaced the starter with a rebuilt one several years ago. All seemed well, but, on one occasion in the first few days, when my wife started the car, the solenoid stuck and it didn't disengage from the flywheel after the engine started. Made a hell of a noise. Shut off the car, and next attempt seemed fine. But I looked under the hood, and it appeared that something on the starter had overheated during this, as there was a solder drip. I don't remember the exact details re the solder, but I really didn't want to return the unit and do a reinstall, so I simply hoped for the best.
Everything was fine until the other day. My daughter called that the car wouldn't turn over. Exercised the shifter (automatic), but that didn't help. Then, after being towed, the driver tapped on the starter, and it started working again. Hasn't failed since.
Looked at it this morning. Here's a pic:
I removed the green wire, and noticed that when shimmying it off, the terminal seemed to move a lot - not solid with the solenoid body. I then noticed that the rivet indicated by the top arrow, was sticking out maybe 1/8" inch. It pushed back in very easily (ie. loose). So I'm thinking that this problem is because of an intermittent contact from this terminal.
Is anyone familiar with the internal structure/connection of this terminal? If at all possible, I'd like to try to secure it's electrical connection, without having to remove the starter. Was thinking I may be able to clean up what I believe is a rivet connection shown by the bottom arrow, and maybe do some kind of solder tack, such that the terminal has a more substantial electrical contact through to the inside of the solenoid. Or I suppose I could simply try to get a solder tack on the center pin of the rivet, and solder the green wire there.
(Or maybe I'm just dreaming - I might actually make it worse - and I should just bite the bullet and remove the starter).
Thanks,
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David Armstrong - '86 240(350k km?), '93 940T(270k km), '89 240(parts source for others) near Toronto
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