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stigomery



Member Since: 10 May 2016
Location: Cambridge
Posts: 277

United Kingdom 2004 Defender 90 Td5 HT Belize Green
Overhauling the starter solenoid
My starter solenoid is on the way out and I have a service kit ready to deploy. I was going to do it at the weekend and had assumed I could probably do it in-stiu, in fact I'm sure I've read instructions on doing so somewhere but cannot find them.

Once I had the front wheels up on ramps it became clear it was a lot tighter in there than I thought.

Having read that getting the starter motor off can be a real ball ache is it possible/wise to do in situ or should I dedicate a day (yes, I might be that inept) to getting the starter off and doing in on my workbench?
Post #645384 21st Aug 2017 10:14am
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
I'd take it off personally, removing the top bolt is the difficult one, if you can source an assistant it gets much easier!

My method is to have a person underneath with a ratchet and a long extension, and the other person reaches in from the top to guide the socket onto the bolt.
Post #645390 21st Aug 2017 10:37am
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dorsetsmith



Member Since: 30 Oct 2011
Location: South West
Posts: 4554

15mm socket 6 point type ^
Post #645421 21st Aug 2017 12:35pm
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 556

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
Removing the starter is a bit hard, because of the top nut. Replacing the solenoid internals with starter still in car is possible, but it is a bit blind-work. I have done it once on Discovery2, after 1 hour long fight with the top bolt. Some years later, we had to remove a lot of parts from engine to remove the top bolt. And we found, that some used some thread locking glue on the nut. Shocked
3/8" 15mm nut is the key tool. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #645425 21st Aug 2017 1:22pm
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stigomery



Member Since: 10 May 2016
Location: Cambridge
Posts: 277

United Kingdom 2004 Defender 90 Td5 HT Belize Green
Cheers chaps

Does it require a flexi/UJ extension bar or will a simple straight extension do the trick on a 3/8" ratchet?
Post #645426 21st Aug 2017 1:34pm
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 556

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
Flat ratchet and extension with the right length. No need for any flex.
I have bought 1/4" 15mm nut and it is even easier, but 15mm is not easy to buy in 1/4" size. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #645488 21st Aug 2017 6:24pm
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Dave T



Member Since: 07 Jun 2013
Location: Glasgow
Posts: 487

United Kingdom 1994 Defender 90 300 Tdi SW Cairns Blue
I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last 2015 RRS Autobiography SDV6
1994 Def 90 300tdi
Post #645582 22nd Aug 2017 6:12am
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MadTom



Member Since: 10 Sep 2013
Location: Olomouc
Posts: 556

Czech Republic 1999 Defender 130 Td5 HCPU Baltic Blue
I have better experience - during last 5 years I have made quite a few of these solenoid repairs, without any return. 50/50 I made also at least clean and re-grease of the starter gearbox. 50/50 only, because on half of them the screws were so tight, that I let it be, rather then breaking them. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo Smile
Post #645583 22nd Aug 2017 6:19am
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stigomery



Member Since: 10 May 2016
Location: Cambridge
Posts: 277

United Kingdom 2004 Defender 90 Td5 HT Belize Green
Dave T wrote:
I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last


Really? Starter motors for the Td5 are around 150 quid, the repair kit is 14 quid. My starter motor was replaced in 2013 so i would expect a lot more life out of the unit itself than 4 years. It's just a sticky solenoid and a tap with a lump of wood frees it when it happens (twice in the last 12 months)... for now a repair will do me...
Post #645594 22nd Aug 2017 6:58am
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 1994

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
Post #645748 22nd Aug 2017 8:55pm
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Dave T



Member Since: 07 Jun 2013
Location: Glasgow
Posts: 487

United Kingdom 1994 Defender 90 300 Tdi SW Cairns Blue
stigomery wrote:
Dave T wrote:
I've done a couple of these on my 300tdi, to be honest, it would have been cheaper and easier just to get a new starter straight away rather than keep on paying for solenoids and then eventually a new starter, the replacements just didn't last


Really? Starter motors for the Td5 are around 150 quid, the repair kit is 14 quid. My starter motor was replaced in 2013 so i would expect a lot more life out of the unit itself than 4 years. It's just a sticky solenoid and a tap with a lump of wood frees it when it happens (twice in the last 12 months)... for now a repair will do me...


May be different, but the only solenoids I could find were £30, where did you get one from? I got a starter from here, has been really good

https://www.directautoelectrical.co.uk/par...amp;cat=12 2015 RRS Autobiography SDV6
1994 Def 90 300tdi
Post #645793 23rd Aug 2017 5:41am
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stigomery



Member Since: 10 May 2016
Location: Cambridge
Posts: 277

United Kingdom 2004 Defender 90 Td5 HT Belize Green
Linky:

X8R
Post #645826 23rd Aug 2017 8:00am
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