SanDiego928

Today with my friends help, we worked on my 81 to rework the starter wiring and add a solenoid relay to fix my no-start issue when hot.

We did add the solenoid relay and reworked all wiring near the starter. Upon initial start the plunger/piston did retract and the starter engaged and started the car right up. At 2nd start, the starter now just spins.

Notable facts:

1. For 3 years jumping yellow wire to engine bay jump post always started the car in an emergency.
2. Starter solenoid was removed to get to the top screws.
3. At one point turning the solenoid downward, the plunger / piston did fall out of the body and spring flew off but was found.
4. We did reinstall piston a few times thinking the alignment was causing the starter not to engage.
5. Starter solenoid appears to work in both directions, in and out.
6. Starter spins but does not engage.
7. Starter lever in front of solenoid piston is hard to move manually.
8. The starter was not removed.

Suggestions welcomed on fix and why the lever in the starter is not pushing the gear into the flywheel. Do these get stiff and not work freely or get stuck when the solenoid piston retracts? What could I have mucked up?

Thanks, Mark

Mrmerlin

suggest to remove the starter and rebuild it on the bench.
NOTE working on the starter while still attached to the engine would be my last choice

SanDiego928

Thanks

Mrmerlin

grab a set of these, the 8mm allen will make it easy to remove the starter bolts.
NOTE dont use the ball end to fully tighten of break loose the bolts. this could damage the tool or bolts

James Bailey

You can get a used starter for $100 from 928 International with a one year warranty....the adding a Ford relay was a common fix for 914s but rarely done or needed on a 928.

Alan

Agree with Jim - if you are having this much trouble (and for this long) - I'd be (having someone who knows how) rebuilding the starter properly on a bench, or get a rebuilt replacement and then also swap out the ignition switch electrical part (for a good OEM one). This is not a typically unreliable part of the system - good parts will make it work fine (even without a relay).

Alan

SanDiego928

All the comments appreciated, thanks.

After some thinking about the plunger falling out and Jim's comment I may as well just replace it with a 928 intl used starter. What the hay. The BBQ every year is worth it on its own. Yum.

The jump post to yellow wire made me feel relatively safe traveling. Hope to fix permanently.

Thanks again guys.

SanDiego928

That Ford relay work-around I found here with a nice diagram. Also found it posted in some links. Thought that was worth a try and I would learn something too. And I was able to fix some nasty wiring also. Next up - the alternator.