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  #1  
Old 12-01-2003, 08:39 PM
dieselbeagel's Avatar
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Starter

I was up and about on Sunday, when 83 300D would not start. I could hear a click at the starter area. I checked the lights -- good and strong.

My problem is either the solenoid or the starter. The previous owner had replaced the solenoid only. I am going to replace both.

Does anyone have an suggestions on how to do this. I have heard that the 300D starters r kindof tedious.

While I am at it, I am also replacing the neutral safety switch.

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  #2  
Old 12-01-2003, 10:22 PM
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Location: Michigan
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I remember the starter job as a 'pain in the butt'. However, it was my first job on the car ('85 300 TD). I was surprised when I could slip it out without removing any suspension parts.

The incredible challange as I remember it was the feet and feet of extensions to get at that one starter bolt. If I remember, I had two extensions and two swivel joints before the socket. Fortunately its an inset allen bolt so slipping was not an issue. If you strip that one, buy another car.

A simple search will yield the process and the bolt sizes.

The good news is that you take it out, get it rebuilt and put it back in for $100 or so. Then you go to sleep and feel good about how much cash you saved.

Don
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DAILY DRIVERS:
'84 300DT 298k (Aubrey's)
'99.5 Jetta TDI IV 251k (Julie's)
'97 Jetta TDI 127k (Amber's)
'97 Jetta TDI 186k (Matt's)
'96 Passat TDI 237k (Don's
'84 300D 211k Mint (Arne- Undergoing Greasecar Conversion)

SOLD:
'82 240D 229k (Matt's - Converted-300DT w/ 4 speed
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  #3  
Old 12-01-2003, 10:42 PM
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Jack it up high enough so you have room to work near the back of the transmission. Two feet of extensions and a universal joint should work. A wobble extension also may be useful. I use 3/8 since the space is small and then an adaptor to put 1/2 inch breaker bar on to get them loose. On a 77 300d non-turbo, the starter comes out over the top of the tie rod when the wheels are turned hard to the right. The turbo has a different configuration of the exhaust pipe so yours may come out another way. Should take less than an hour to get it out and a new one in.
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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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  #4  
Old 12-01-2003, 11:08 PM
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I found a heavy duty starter ( the parts bin ) for $ 129.00, delivered. That includes a complete starter & solenoid.

Is it worth the hassle to get the old starter out, send to a shop, pick it up and reinstall it , for savings of $29.00. I would still be stuck with the old solenoid. Or do they rebuilt the whole thing ?
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  #5  
Old 12-02-2003, 09:31 AM
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I need to replace the starter on my 240D. Before I commit, can the heavy duty Bosch in the 300D and 300SD replace the light duty found in the 240D? I've found them for ~$133.

The current starter still has trouble engaging. It just whirrs. After a few tried, it will catch, then you can start it. I rebuilt the starter this weekend with another parts starter I had in hand. The parts starter had much less wear, but had an open commutator on the armature. I cleaned the commutators on the old one and swapped the solenoid. It now spinns like an SOB but rarely engages.

I bench tested them both. They both would kick out the gear just fine but my power supply didn't put out enough to spin the armature. The starters were drawing 32-33 amps. I was quite supprised. I thought that would be enough to get it spinning, but I guess not.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #6  
Old 12-02-2003, 09:52 AM
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Michael, there is something simple and basic missing in your test.. although without seeing it happen I can't tell you what it is...
Are all the wires hooked up just like they would be in the car?.. sounds like you only have the solinoid hooked up....use a car battery to test.... 33 amps should have turned it fine off the car... check it in different positions..maybe a bearing is worn to the point where if you have it on one side it moves away from something it should be touching... this is hard without seeing it.. but I think you should stay in there and keep trying before making any decisions....Right now it may not even be anything wrong with the starter.. just your test procedure...
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  #7  
Old 12-02-2003, 09:54 AM
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Yes, I believe the later heavy duty starter will fit the 616 engine. I recently put one in place of the standard one in a 77 300d. The heavy duty starter does spin the engine faster.
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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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  #8  
Old 12-02-2003, 12:30 PM
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There is one thing that is different about my test than being on the car. I connect both the solenoid (little wire) and the motor (big wire) to the power supply, instead of the motor being permantly powered up. This way, when I turn on the supply, they both are connected to 14 volts at the same time. Maybe one needs to receive power before the other.

Does the bendix throw out the gear into the ring gear then spin the motor, or does the motor start to spin and then the gear mesh into the ring gear? I believe it would have to be the former. I did notice that the ends of the starter gear is a bit worn and rounded compared to the other, but I didn't think it was enough to make a difference.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #9  
Old 12-02-2003, 03:38 PM
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Since I'm up in the cold country (don't you Canookers chime in now) and the car will be outside and I don't have a block heater, it might be better to get and put in the heavier duty starter.
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Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

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  #10  
Old 12-02-2003, 08:19 PM
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Location: central Texas
Posts: 17,281
I think it is always nice to have the more powerful stater... but also go through and be sure all the wire connections are clean an tight.....and if you have old wires check up under the covering to see if they are corroding.

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