The problem started when I would turn the key and no starter !!!
So, its the solenoid right ?? Well, I replaced it with a known good starter from another 300SD. It worked for a bit but within days I saw the problem again. In all these cases I could use a screwdriver to jump the 'S' terminal and the + terminal and start it.
Or, just short it for a second and then it ALWAYS cranks using the key.

Thats the puzzling part,

When it became more and more frequent I swapped in a 'brand new' starter, redid the wiring from the battery and the bus on the fenderwell. All new wires, heavy guage wire from the battery positive etc:-

worked great for 2 days and then the same symptom.

what gives ?


this is on a 1980 116 body 300SD

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1982 300SD (214 k, excellent shape) kidmobile running mostly biodiesel, gets 31 mpg hwy with 2.82 rear from a euro 500SEL



1976 115 body 240D 4-speed (traded for Jeep parts) - Engine lives on in my CJ7

grimgaunt

I am supprised no ones come up with something. The only thing that comes to mind, but I think it was 240Ds, is a thread a while back about starters that were of a later year that would fit but would fail soon. Seems an early (77-80) 616 starter will seem to fit in the later 616 but there slightly differant enough cause it to fail. Probebaly wouldnt apply to 617 but at least I can help keep your thread allive, Do a search, its not too far back.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Check ur Neutral Safety Switch(NSS). It is found on ur tranny, next to the modulator.

Also check ur linkage bushing while u r down there.

If u do find play (left door to right door) in the NSS, take a nylon tie and tie the NSS to the linkage( tie the arm of the NSS to the linkage on it). This may solve ur problem.