Hello all,
New to the forum and have aquired a 1985 300d California model. I have been studing all the info here about starters and finally pulled my starter out once I figured it was the solenoid. Benched tested once out and it definitely was the solenoid so I replaced and tested again and worked properly. So I installed it and the first 2 startings was fine and the the 3rd time it made a grinding noise sorta like if you were to try to start a car when it was already running. I have started it several times without incident and then it will do it again. Prior to pulling starter it never did this only the intermentent clicking thing. I am wondering what could be going on, and should I pull the starter again (really not wanting to go there again). Could I have installed it wrong. On the california style starter there are 2 holes on each mounting ear, could I have offset those? I think that the gears are not meshing or fully engaging. I suspect I may have to pull this again, ugh!
thanks in advance for your help.

Maybe your ring gear and/or Bendix gear are/is shot from the bad solenoid.

Sixto
87 300D

If you put the bolts in the alternative holes, would it put the bendix closer to the ring gear? If so, that could be your problem. I haven't seen starters with two different mounting bolts. I'd take it out and do some measuring, comparing the holes with the original starter. You don't want to destroy the ring gear because replacing that is a much more difficult job.

__________________
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

Have not removed the starter on my 300D recently, but on my SL, there is a spacer between the starter and the housing. This spacer controls how far the gear meshes with the ring gear. Did do have one and was it put back?

When my starter was out, I had local garage (who did the work) rotate the ring gear and checked for wear or broken teeth - just a little wear on tips of teeth because starter had not been fully engaging. That happened because of sticking solenoid/bendix (or whatever MB call it). They forgot to put the spacer back, but as it turned out, the new starter worked fine without it.

Good Luck with it. It's useful to get someone with a hoist to help!

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Graham
85 300D,72 350SL, 98 E320, Outback 2.5

I agree that a hoist would make this some what easier. I am going to have to pull it because I don't want to make things worse with that grinding. I will look at the bendix as that seems not to be fully engaging with the flywheel and that is causing the grinding? I did not see any spacers. At this point it isn't doing it all the time so it does engage properly so maybe the bendix is weakened. Really not looking forward to doing this again.

Can the ring gear be rotated or turned over and how?

Did you install a new solenoid or a used one? Did you lubricate before assembly? Did you check for worn bushings/ bearings? Did you assemble everything correctly? Did you bench test it before install (by free spinning it while being powered)? You can get a good idea by listening to how the starter motor sounds and smells while free spinning and measuring the free spin rpm with a photo tachometer.

__________________
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

I usually replace the starter, cost not much different than replacing the bendix and less work

__________________
1977 300D Lost coolant while someone else was driving
1983 300D Can't run without oil
1985 300SD (gone but not forgotten)
1990 300TE 4matic Sold
1991 Yamaha Venture
1975 Kawsaki 250 triple
1974 Honda 200CL
1951 8N Ford
2008 Wildfire 650C

Bosch solenoids rarely go bad. It's usually binding due to rust in the plunger (the part that moves), it can be cleaned/lubed then they're good as new. edit: W123 diesel Bosch starters do not use a Bendix, they use a centrifugal clutch.

__________________
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

same thing no?

what's the difference between a bendix and a centrifugal clutch?

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

No, they're not the same. I meant overrunning clutch, not centrifugal clutch.

Read the 3rd paragraph under Electric Starter in this link to see the difference.

Starter motor - Wikipedia, the free encyclopedia

Bendix drive was used in starters before (roughly) 1960's, after that, it was replaced by the overrunning clutch design.

__________________
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

Thanks for all the input. It came down to that I had to pull it out again before it did some damage so I did pull starter yesterday and took in to the guys at the auto electric that sold me the solenoid. They thought it might be a bad clutch but that did not turn out to be, instead they had sold me the wrong solenoid. Bosch listed 2 part numbers and this one I got did not match in the real world, the throw on the solenoid was to short. So they switched solenoids and I put it back in last night and so far so good.
Blood, sweat and tears putting it back in, coming out it was all gravity.