348/355 intermittent starter problem fix

Here's something to check if it sometimes works, sometimes doesn't. The pic is the inside of the starter solenoid with the piston removed. 3 little bolts to take the backplate off and it slides out (and back in just a easily). On the left side of the solenoid housing is the terminal for the battery cable. On the right is the cable to the starter motor. When you engage the starter, the piston pushes the bendix drive into the flywheel to turn the motor over. ALSO notice the copper ring on the piston (lower left of picture). That ring makes contact with terminals on the inside of the solenoid to charge the starter motor. Copper colored as well. The one on the left is attached to the battery cable, grommeted thru the solenoid housing. If your battery cable has ever been attached by a gorilla, then the entire contact assembly has probably turned, ruining the alignment of the two terminals inside the housing. Then, when you remove the battery cable subsequently, it goes out of alignment the opposite way! The lesson here is to support the bolt from turning by holding the battery cable in position when loosening it, then don't overtighten the thing. It's not like it's gonna go somewhere, you're just making an electrical connection, not tightening a rod bolt. The copper ring on the piston get somewhat buggered up by the bad connection, but you can file off the buggers and realign the terminals. Problem solved (Hopefully)
Image Unavailable, Please Login

 

Yes, this pic shows the terminals after some cleaning. Sounds like a "boost" relay is something that maybe all front battery cars might want to consider to prevent future problems. Are they generally available? Any source? Thanks!

 

Good man!