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I checked it this morning. After about 5 attempts with a hand-held starter switch, and about 10 using the ignition switch, no problems. After a heat wave, the morning of the problem was the coldest in a while. I suppose this could have been a factor, but we're talking relatively minor variations here (15 C); I wouldn't think that this could trigger such a problem.
I also noticed that solder had dripped onto the ground underneath it, looks like from where the solenoid terminal attaches. It apparantly heated up rather well.
I know I should probably just go ahead and swap it out, but there's still an outside chance this was some kind of ignition switch or wiring issue, holding 12 volts on the solenoid after starting. I'm thinking I may hook up an idiot light to the solenoid terminal and drive it for a few weeks. If the problem happens again, I'll at least be able to determine if it's strictly a sticking solenoid, or if something is driving the solenoid with 12 volts at the time.
Of course, a starter failure is a PITA, but I'll rely on my CAA towing if it fails. I'd rather be sure it's a sticking solenoid before going to all the trouble of replacing it, only to find it's the ignition, and frying another starter in the process (thus a 3rd replacement!). Either way, in a few weeks, I'll replace it.
Do you think there's a downside if it "sticks on" again? I wouldn't think it would affect the flywheel - it would just screw up the starter motor more if it overheats. I'll listen carefully when starting, and pack a fire extinguisher!
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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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