924Board.org

Smoothie · Last edited by Smoothie on Tue Mar 22, 2005 4:08 am; edited 2 times in total

<This (pics)> is the solenoid that gave me trouble all winter even after being removed and cleaned in the fall (no start & no click at temps around 20F and below). (The plunger at upper-left was cleaned in fall '02.) In April '03 it failed completely - clicked, but no start. I cut it open and found what you see. Corrosion everywhere, especially on the electric contacts. Purchased from Performance Prod, made in Brazil. I'm sure it would have fared better in Brazil or So. Cal, but most of us don't live there. Apparently, poor sealing let moisture in. I put an old previously-replaced Made in Germany solenoid on the starter after cleaning its' plunger and it's working fine.

If they don't click, the plunger might just need cleaning.
If you get a click, but still no start, the internal elec contacts might be garbage as in the pics.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

Lizard · Posted: Wed May 07, 2003 1:36 am Post subject:

what r u talkin about it looks fine

that would definatly cause it though
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3 928s,

jpab924 · Posted: Wed May 07, 2003 1:44 am Post subject:

I had a replacement boat starter do the same thing. I opted to buy an automotive starter because it was a ton cheaper than a marine starter. I learned a lesson from that fiasco.

Smoothie · Posted: Wed May 07, 2003 2:04 am Post subject:

btw - it was that solenoid plunger getting gunked up so often that prompted me to finally put a cover on the inspection hole at the bottom of the bell housing (924T). Hopefully it'll stay clean longer now.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

924RACR · Posted: Wed May 07, 2003 2:40 am Post subject:

You're doing better than I am... 1 weekend on a new German one...

I still can't start my racecar when hot. Seriously bummed about this one, no fix yet...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Smoothie · Posted: Wed May 07, 2003 3:53 am Post subject:

I have the exhaust wrapped in the area adjacent to the starter and in addition thought about putting an insulating cover on the starter, but you have to figure a bunch of the heat is transfered through metal contact from the engine to the starter so an insulating wrap might just hold -in- more heat than it keeps out. (I've had the no starter when hot on warm-hot days problem too.), but I've always found the solenoid gunked-up when this has happened and cleaning was the best solution - obviously yours shouldn't need cleaning after 1 week though...

Another thought I had but haven't tried yet is one of those aluminum cooling fin things that are made to go over an oil filter. They have small and large sizes - maybe try fitting a larger one over the starter - or modify a smaller one to fit the solenoid.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

924RACR · Posted: Wed May 07, 2003 4:28 am Post subject:

The other thought I have, though perhaps extreme for a street car, will be to install a new fresh air duct and small computer blower fan to pump in fresh air to cool the starter after shutdown, improving the recycle time. I agree about an insulating cover and heat transfer from the block; I currently have an insulating blanket on the starter, and think it's aggravating the problem! I will be removing that as soon as I get a chance.
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Smoothie · Posted: Wed May 07, 2003 4:42 am Post subject:

The blower's a good idea. I'd suggest one of those small sqirrel cage type blower fans for an old VW's heater. The right size duct hose fits right over the round outlet and they move lots of air. A couple summers ago when it wouldn't start and I had access to a water hose, I sprayed cool water on the starter to move things along, so cooling air should do it too.

One more thought - assuming that metal expansion has something to do with the starters not working in heat - maybe machine down the OD of the plunger slightly.
Another consideration is of course the wiring and the fact that hot wire doesn't conduct as well as cool wire - wondering if heat insulation on the wiring would be of any use.

Also - I noticed that the solenoid from my '86 4 cyl Cherokee will fit the Porsche. (The Cherokee has a Bosch starter.) It attaches by 3 screws of the same thread size/pitch and appears identical in every way except for a spring loaded attachment at the end of the plunger (that could be removed if necessary) and the small wire attaches via spade connector instead of a nut. -So I won't be suprised to find myself giving the Jeep solenoid a try in the Porsche sometime soon. I have a spare new one waiting around to be useful.

_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

924RACR · Posted: Wed May 07, 2003 10:12 pm Post subject:

Agreed about the tolerances. I plane to take mine apart and clean it/play with it... maybe rebuild with synthetic grease.

My wiring is new, and well insulated.
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Smoothie · Posted: Thu May 08, 2003 7:32 am Post subject:

<Jeep Solenoid Pics>
This is the Jeep Cherokee solenoid that I mentioned. It seems to be from the same manufacturer that made the one that I just removed - the rusty mess that lasted 1.5 years. I'll be performing some weatherproofing enhancements of my own before using it. It'll fit - just need to use a short adapter wire with female 1/4" spade connectors at each end to attach the small wire.
_________________
"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox