1984 1.6D Starter Motor Rebuild

An alchemy of sparks, copper wire and earth

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boatbuilder
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1984 1.6D Starter Motor Rebuild

Post by boatbuilder »

I just took my starter motor apart tonight as it was refusing to start, not even a click.
Tried the usual suspects - gearbox ground strap and connecting wires direct from the battery to the solenoid etc.
As a last resort tried hammering the solenoid to see if it would unstick or something...nope.
Connecting a positive wire direct from the battery to the solenoid didn't do anything except heat up the solenoid to the point where the plastic started melting on it.

I had read somewhere that you can take the solenoid apart and clean the contacts inside so I tried that but soon found that this particular solenoid can't be dismantled because the black plastic bit is held in place by the metal cylinder that it crimped over it and it would be practically impossible to uncrimp it.

Anyhow, you can get a replacement solenoid for €18.
http://www.ebay.co.uk/itm/150974080321" onclick="window.open(this.href);return false;

No need to buy a new possibly cheaper brand starter motor if you're willing to get the parts and service your old Bosch one.

Parts that can be replaced are:
Solenoid €18
Brush replacement choice of either A or B (I'd go for B)
(A) Motor Brushes (requires soldering the 4 brush wires onto the old brush box holder) €7
(B) Entire brush box holder with new brushes already attached (requires soldering one big wire on)€10
2x Copper bushings €2 each

Some more info that might be useful to someone else undertaking the same job....

VW T25 1984 1.6d starter motor
Bosch starter Motor
Bosch no: 0001317016 (stamped on motor casing)
VW No: 068911023J (stamped on motor casing)
Solenoid 131586
You can get a set of four brushes or a whole brush box that has to be soldered on... would take big soldering iron.
Also there is a copper bushing at each end of the motor, just pushes in...

Alternative Part Numbers for the whole starter motor:
BOSCH 0001110009
BOSCH 0001110010
BOSCH 0001310013
BOSCH 0001317006
BOSCH 0001317011
BOSCH 0001317012
BOSCH 0001317016
BOSCH 0001317017
BOSCH 0986010940
BOSCH 0986013350
BOSCH 1094
BOSCH 1335
FIAT / MARELLI 943251675
FIAT / MARELLI 943251701
LUCAS LRS00564
LUCAS LRS00662
LUCAS LRS564
LUCAS LRS662
VALEO 433334
VALEO 433336
VALEO VS343
VOLKSWAGEN 068911023D
VOLKSWAGEN 068911023DX
VOLKSWAGEN 068911023J
VOLKSWAGEN 068911023JX
VOLKSWAGEN 068911023M
VOLKSWAGEN 068911023MX
0001317006
0001317011
0001317012
0001317016
0001317017
0986010940
0986601941
111062
DRS0940
11130910
11130772
AZE2577
AZE2540
IS0772
16961
LRS564
943251675
01317016
433334
068911023D
068911023DX
068911023J
068911023JX
CS299
CS358
1984 1.9D (AEF Code) T25 tintop

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