96 T&C starter (3.8L)

While I have complained about some T&C components failing early in life, the
starter is clearly not on that list. Now, at 170K, the starter fails to
start every so often and it's getting worse. I know what it is: it's the
starter solenoid. I hear it clunk into place when I turn the key but, alas,
the big old contacts just ain't what they used to be. So one has to try
again and again until getting lucky. This will eventually become terminal.

What I have done in other cars is simply swap out either the solenoid or the
solenoid contacts. Why not? The starter is an extremely low duty cycle item
that rides along dormant for about 98% of the time. When it is called upon
to do it's thing, the big electrical stress item is that poor solenoid. With
a new one, the electrical stuff in the starter (stator and rotor windings,
brushes) and the bearings and bendix drive will go on and on.

Someone, please make my day and tell me the solenoid is a replacement item
in this starter!

Ken

 

More precisely, the solenoid *contacts*.

Better: The solenoid *contacts* are replaceable items. See here:

http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

 

Sorry, the solenoid is not replaceable.

The contacts inside however, *are* replaceable.
The contacts are 29 and 39 cents apiece, and are available here;

http://www.autosupply.ws/contacts.htm

You want the 3401 and 3404 part numbers

 

Thanks Daniel and aarcuda69062. This is even better than I thought. I used
the term "solenoid" as the last couple of repairs I have done like this
(over many years) had the contacts sealed inside the solenoid housing.

Of course, if I don't have to change the electromagnet itself (which, aside
from the contacts, should last about 100 years), then I am certainly a happy
camper.

There is always a downside....probably have to pull the engine to get to the
starter.

Again...thanks for the help.

Ken

 

Nope. The 3.3 / 3.8 starters are very easy to remove.

My pleasure.

 

KWS wrote:

Better than that, all you need are the two solenoid contacts (about $8
at an alternator repair house) and possibly the plunger contact disk
(about the same price). Plus an hour of your time to R&R the starter and
replace the contacts, although some folks replace the contacts with the
starter still installed in the vehicle.

 

You're making my day here, Steve. Thanks.

Ken

 

Usually, anyway. Sometimes one runs into the steel bolt/aluminum
housing thing, but it's usually nothing a little muscle and the proper
tools can't solve.

 

Fortunately, Walter, this type of corrosive activity is considerably less
here in the SF Bay area. I just bought a second hand car for one of my
daughters and had to change the catalytic converter. The car came from "back
East" and I forgot how nasty rust can be, having been spoiled by relatively
corrosion free climates for the past 25 years.

 

You're right ... I hadn't considered that some places aren't the
NorthEast part of the country where rust and corrosion rules. It does
get pretty nasty sometimes, though... the rust, I mean.