22R Starter Motor Solenoid Switch Repair

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Tim86
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Fri Oct 12, 2018 10:58 am

Hi Chaps

This is my 22R's starter motor:
IMG_20181011_184020.jpg
I got the typical click whenever I turned the key i.e. power was going through both wires and the solenoid was working (also checked wires with voltmeter), just the starter motor power supply switch within the solenoid was not making good contact. Generally after a few tries the motor would spin.

I have got the solenoid piston out of the cylinder but the rest of the contraption appears rather sealed. You can see on the rear of the solenoid body there is a punch mark where it has been deformed to fix to the switch assembly. Is it possible to get in there and clean up the switch contacts or replace the switch, or do you have to replace the whole solenoid??
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niclemaitre
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Fri Oct 12, 2018 11:20 am

In my experience, it's better to replace the solenoid than go through the schelp of stripping it. Been there, ruined the T-shirt. Solenoids are not particularly expensive
Happy trails
Nic

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Tim86
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Fri Oct 12, 2018 11:22 am

Thanks Nic. From where did you attain your new solenoid?
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Mud Dog
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Fri Oct 12, 2018 6:39 pm

This is the most common problem with all starters. The main contacts in the solenoid wear down by the arcing that takes place with each start. These copper contacts are replaceable and are generally available from dealerships as well as many of the after market spares outlets. I know that Midas keeps for the more common range of starters and in fact just last week I replaced the contacts in the starter on the Rav4, which I got from Midas for the princely sum of R24.00 (trade price). Diesel Electric also carry spares.

I've done this repair to a number of starters on my vehicles over the years without any problems thereafter. One in particular had a very high mileage and the original contacts had already been replaced prior to my ownership and although the contacts were not badly worn, the copper contactor ring on the plunger itself was. In that case I replaced the plunger as well and as I recall it was also not expensive ... somewhere in the region of about R40 at the time.

IMO it's well worth stripping and replacing the contacts. When you reassemble just brighten up all the connection points and lugs. There are also normally water seals in the form of washers or o-rings on the external contact bolts - replace these if they are broken or perished. Lube the bendix at the same time with a little MS grease or lithium grease. You'll be good to go for many more years. :winkx:
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Fri Oct 12, 2018 6:48 pm

P.S. I cannot speak definitively on this but it's my experience that the brushes in the motor itself seldom need replacement and probably last the lifespan of the vehicle. Bearings and bushes also last very well unless there has been a lot of water ingress.
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
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Tim86
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Fri Oct 12, 2018 7:40 pm

Thanks Andy, I'm a bit stuck as the black bakelite solenoid end cap casting appears to have been 'press' fitted into the metal solenoid cylindrical housing. I say press due to lack of a better description - you can see in the pic where the metal housing has been punched to fix the cap in place. There is a thin sleeve within the solenoid in which the piston travels - I am fearful to try and pull this out as it may get damaged and prevent smooth operation.
The non-removable end cap and sleeve prevent me from getting at the contact points.

Judging by the identity number it appears to be an original even though it has been meddled with in the past - have you repaired this specific solenoid before and experienced the same obstacles?
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Mud Dog
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Sat Oct 13, 2018 2:08 am

No, I've never repaired one like that and I assume that you've removed it by releasing the two through-bolts from the bendix side of the solenoid. Looking at your pic more closely I see what you're up against and it looks like the contacts are moulded into that black end cap.

In a case like that I would imagine that the complete solenoid would be available as a unit. Still worth replacing just the solenoid instead of the complete starter. Phone around to the agents, Diesel Electric and Midas to enquire on availability and price (sometimes the dealers are surprisingly competitive). Then take it with you as a sample to whichever one you decide to go to just to make sure it's the right thing.

Good luck. :winkx:
When your road comes to an end ...... you need a HILUX!.

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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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Tim86
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Mon Oct 15, 2018 11:42 am

Dealer informs me that the solenoid & starter is discontinued although Auto Magneto here in Die Kaap stocks the solenoid for R260.00 although I haven't bought one as I seem to have got it operating 100% so far.
I sprayed some electrical contact cleaner/lubricator deep into the unit and gave the little push button within a good couple of jabs - the motor spins at the first turn of the key now.
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niclemaitre
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Mon Oct 15, 2018 12:06 pm

I got mine through my local Autoelectrician, Mettes Auto Electrical in Stellenbosch
Happy trails
Nic

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Mud Dog
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Mon Oct 15, 2018 12:55 pm

Good to hear Tim, but I doubt it will be a lasting solution. The cleaner could have improved the contact area sufficiently for now, but the main problem is errosion / wear. I suspect the problem will come back to haunt you sooner than later. Might be a good idea to get that solenoid while they are still available. :winkx:
When your road comes to an end ...... you need a HILUX!.

Image
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Life is like a jar of Jalapeño peppers ... what you do today, might burn your ass tomorrow.
Don't take life too seriously ..... no-one gets out alive.
It's not about waiting for storms to pass. It's about learning to dance in the rain.
And be yourself ..... everyone else is taken!
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Tim86
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Mon Oct 15, 2018 3:59 pm

Will do! Next paycheck :thumbup:
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