Dodgy 200tdi starter - repair or replace (USA)

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limeypete33

Member
Posts
58
Location
CT, USA
Hey guys, I'm in CT, so keep that in mind!

Starter has an intermittent issue where it will spin up and crank the motor but sometimes the pinion will disengage while still spinning.

I have always got it to start but it just takes a few goes sometimes. Especially when it's cooler out.

Now it's warmer I decided to pop it out and I could grease the solenoid cylinder (thinking it's sticking a bit) but it's such a pain to put in/take out, I would rather replace the solenoid or even better send the unit out to get refurbished.

What do you guys think?
 
They are easy to strip once on the bench, easy to repair to.
The hardest part is removing them from the car, but assuming its a defender 200tdi with defender 200tdi engine? it looks impossible bit is doable with the turbo/downpipe heatshield removed.

Have you checked the earth straps? if not sure just add a battery jumper cable from battery negative/ground to the engine lifting eye, then try starter again.
 
What lynall said. It’s a bit fiddly to remove but is doable.
If it’s not your daily I would send it out for refurb then don’t worry about it again forever.

run an extra earth to the battery (jump lead on engine to battery -ve) first to rule out any earth issues
 
flat said:
What lynall said. It’s a bit fiddly to remove but is doable.
If it’s not your daily I would send it out for refurb then don’t worry about it again forever.

run an extra earth to the battery (jump lead on engine to battery -ve) first to rule out any earth issues
Click to expand...

So this is my question really. The starter is out already and partially stripped (just took the solenoid off so I could check that out). My preference would be to send it out but does anyone know of a company that works on these?
 
not stateside i dont, but its jsut an electric motor so any rewinders would be able to do it i would have thought, internet search and telephone around would be my best suggestion tbh, and may not be local, might have to post it a ways away from you
 
limeypete33 said:
So this is my question really. The starter is out already and partially stripped (just took the solenoid off so I could check that out). My preference would be to send it out but does anyone know of a company that works on these?
Click to expand...


I used to have to do mine almost monthly as all the water and mud from pay&play sites used to get inside it and gunge it up, all I ever did was strip/clean/rebuild and refit, never needed any parts.
I had two in the end, the bosch one finally gave up the ghost, yet the britpart one is still soldiering on.
The internals of the britpart one are truly cheap, the bosch one was much better made, but like I said it failed first, age unknown as it was originally on my old 2.0 litre diesel.
 
The solenoid does two things when it's energised, the core moves up towards the two 13mm nuts connecting the heavy battery cable to the heavy cable going into the motor so it spins. The 2nd thing it does at the same time is pull the linkage connected to the other end of the core which forces the Bendix into mesh with the flywheel.
If the starter carries on spinning but comes out of mesh then the solenoid is working and I would look at damage or wear to the Bendix linkage, Bendix gear or flywheel teeth.
There should be a pin of sorts which acts as a pivot between the solenoid and the linkage, did you have to remove this to disconnect the solenoid? This may be missing or broke preventing the linkage working the Bendix properly.
I'm not a starter motor expert but I had a ton of grief with my motorhome one and learnt loads .
 
Flossie said:
Oh, and what make is the starter?
Click to expand...
That was my next question, how can I tell? It looks like a Valeo based on the solenoid design and that it has the two long studs that go through the starter casing to hold it in place.

The armature and piston that controls the pinion position moves nice and easy and I'm wondering whether just a light polish and spray with some lithium grease will fix it?

But as I said before, since it's out of the vehicle, if I can track down the bits to replace/clean and do it all at once that would be ideal.
 
Flossie said:
The solenoid does two things when it's energised, the core moves up towards the two 13mm nuts connecting the heavy battery cable to the heavy cable going into the motor so it spins. The 2nd thing it does at the same time is pull the linkage connected to the other end of the core which forces the Bendix into mesh with the flywheel.
If the starter carries on spinning but comes out of mesh then the solenoid is working and I would look at damage or wear to the Bendix linkage, Bendix gear or flywheel teeth.
There should be a pin of sorts which acts as a pivot between the solenoid and the linkage, did you have to remove this to disconnect the solenoid? This may be missing or broke preventing the linkage working the Bendix properly.
I'm not a starter motor expert but I had a ton of grief with my motorhome one and learnt loads .
Click to expand...


Iirc some of the linkage pivot points were adjustable ie offset.
 
limeypete33 said:
That was my next question, how can I tell? It looks like a Valeo based on the solenoid design and that it has the two long studs that go through the starter casing to hold it in place.

The armature and piston that controls the pinion position moves nice and easy and I'm wondering whether just a light polish and spray with some lithium grease will fix it?

But as I said before, since it's out of the vehicle, if I can track down the bits to replace/clean and do it all at once that would be ideal.
Click to expand...
I think I've got a non working valeo in the garage off a 200tdi. I'll go look later and post pics if it is.
 
limeypete33 said:
I'm not familiar with Wasp, do you have a link?
Click to expand...

http://www.wosperformance.co.uk/products/starter-motors/applications/

Screen Shot 2021-05-19 at 07.28.15.png
 
Worth a try, more so if the teeth on the starter gear and flywheel ring gear look ok. No need to refit to vehicle to try, just connect to a battery and small live to touch on solenoid spade. If it holds every time in engaged position good to go.
 
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