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Need to replace starter on '86 740 GLE Turbo Diesel 700 1986

You dont mention what the problem is - does the starter fail to turn, turn sluggishly, just click etc. The starter motor itself is pretty bullet-proof (may need new brushes in which case you need to have a soldering iron). The solenoid contacts wear down faster (relatively).

I recently cleaned and rebuilt both the starter and the solenoid. Dont expect to take those nuts off those 2 bolts that stick out from the back of the starter: I have 2 starters and both of mine were stuck onto the bolt. Use the correct size wrench and you will find that the bolt (which is as long as the starter) will unthread from the other end and the entire bolt will come out.

Regarding the solenoid - again you will need a soldering iron to remove the contact plate, clean it and reinstall it. My biggest challenge was removing the 2 flat-head screws that hold the solenoid to the starter - you need a very good 3/8 or 1/2 flat-head screwdriver with a perfect tip to pull those 2 suckers out as they are really tight, and using anything less than a good screwdriver tip will mess up their heads and result in them being permanently stuck in there. I replaced them with 2 alan screws.

Oh - before I forget - after all that painstaking rebuilding, I found that it was the grounding wire going from the battery to the engine that was bad :( so check the obvious first. Use one line of a jumper-wire set to ground the starter body (the head of the starter-bolt is a good spot) directly to the -ve post of the battery and then try starting again.

Noel






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