I noticed some sparks and smoke coming from the wire connecting the starter to the solenoid after cranking for about 5-8 seconds. The wire was hot. I figured it's a bad connection at the solenoid and went to remove the wire to try to repair it (solder). I put the 13mm socket on it and started loosening. But the nut stays put and the threads/stud spin! Though it seem like there should be, there is no bolt head to hold on the back of the solenoid.

Since the stud appears to just spin in the solenoid, I guessing that means something inside the just solenoid broke. Does that mean my entire starter is toast all just for a bad wire and now stud on the solenoid?

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1986 300 SDL, gray on black, #14 head, 180K miles
1982 300 CD, silver on palomino, 290K+ miles [sold]
1980 300 SD, white on palomino, 500K+ miles when retired [uncle's car - inspiration for the above]

SOLENOID SWITCH
MB# 0001523010
$122.00




.

__________________
ASE Master Mechanic
asemastermechanic@juno.com

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

Sometimes you have to take things apart to find out what exactly is wrong...
forensic autopsy.....

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/diesel-discussion/10414-help-i-need-check-stretch.html

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

The SOLENOID SWITCH is a "multi ton press" sealed unit.

Seriously ? That sounds a little like overkill... ???

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

Luke, when you take it off... how about sending it to me... ?
I have BIG hammers.....

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

Luke, the starter may very well be ok. It's likely just the solenoid is fried.
There is a pictorial about rebuilding the starter somewhere on this forum.
On the subject of rebuilding, stay away from rebuilt starters from McParts.
Most of there are reconditioned with substandard Chinese and Mexican pieces. You will have problems with them. If you are comfortable changing out the starter, follow the instructions on the pictorial and use the OEM solenoid. Or take it to a re-builder, and insist on OEM parts, Or use a salvaged starter. I'd take a good used starter over a "lifetime rebuilt McParts" starter any day.
Jonj

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Jon J.
81 240D

One good method is to find a farm town with an old electrical repair shop which fixes magnetos and generators and starters for tractors..... they know how to deal with industrial type stuff....

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

great thanks for the tips guys. guess I have to R&R the starter and probably replace that solenoid.

The car has 180K miles - is the whole starter going to need to be replaced soon anyway? I'd rather not fix it if it ain't broke, but then more importantly, I don't want to mess with again for at least 50K miles.

__________________
1986 300 SDL, gray on black, #14 head, 180K miles
1982 300 CD, silver on palomino, 290K+ miles [sold]
1980 300 SD, white on palomino, 500K+ miles when retired [uncle's car - inspiration for the above]

The solenoid coil and the elec cotacts are sealed by a crimp on the casing therefore no access. Try pulling on the stud while tightening the nut. My guess is there a square which locks the stud internally that has fallen out of place. The solenoid is pretty robust and usually lasts a long long time per a local rebuild shop. What ususally goes wrong with Bosch starter motors are worn bearings. Take yours apart, check the windings for shorts. If no shorts found, check and replace bearings and brushes if needed, clean and lube and you should be good to go.

ps. I recently "rebuilt" a starter and finally had to put it to the test last week when a pin hole developed in the fuel line under the car and sucked air. I must have cranked that starter for a total of 5 minutes without it slowing down (15 sec ea with rests in between). With my old bad starter I was able to only crank 2 x 15 seconds before slowing to a crawl.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Here is a good starter DIY rebuild thread

An OM617 starter motor is for LIFE not just for Christmas!

CHARLIE

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works