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  • 120 KZ-TE Auto starter motor freshen up.

    Hi all,

    Well... after the last couple of trips out and about MUMSRIG's starter motor had copped a bit of a soaking due to all of the mud trails and water crossings we have been through.

    The first hint was when Tam went to start and the starter motor kicked in and out then in again and soon after didn't want to kick over without a bit of a tap...

    The cost of a new one would be quite expensive (I'm guessing), so I popped the solenoid cover off the back and checked the contacts.. Sure enough they had the green meanies. Below are a few pics and steps to help you go through the process yourself to 'freshen up' the starter motor solenoid if it begins to play up. It will save you some decent coin and is only useful if the contacts are still serviceable.

    Tools required:
    10mm spanner (to disconnect the battery), 8mm short 1/4" drive socket and ratchet (preferably, although a ring spanned will do), long flat blade srewdriver, an extendable mirror, torch, emry paper (120 grit is fine) and a can of contact cleaner.

    The job can be done with the starter still fitted to the car. Solenoid is circled below...


    Firstly, disconnect the battery. Then undo the three 8mm headed bolts and using a flat blade srewdriver pop the cover off. Remove the solenoid plunger and be cautious of the spring as you could damage it if heavy handed.


    You can see the dirty contacts here..


    And here..


    Simply grab your emry paper and tear of a smallish piece and then contour your fingers into the solenoid to emry back the contacts a little bit. They won't need much work to get them cleaned up. Once your happy with the contacts then give them a good hit with the contact cleaner, this will also help clean out any mud etc that may be in there..

    Then run your emry over the the plunger contact until it resembles brass again. Mine still has some pitting but it's not that bad.


    Make sure you re-grease the solenoid plunger (not excessively) as the grease would have been contaminated by water etc over the years.

    Installation is reverse of the above, just be sure to line up the spring as you re-insert the plunger...

    And whalla, all going well you might get another 100,000 klm's out of it :P
    [img]http://i49.photobucket.com/albums/f296/1cut808/MUMSRIG/Mitch-Prado.jpg[/img]

  • #2
    Re: 120 KZ-TE Auto starter motor freshen up.

    Ha Ha Ha Ha Ha Mitch,

    I bet I followed you through the same puddle the other weekend (the one right before our 1st stop at Harvey Dam).

    About 2 days later my starter did exactly what you described. Same thing cleaned the contacts with a file, back together and sweet as. Starts better than it ever has.

    I dropped the starter from underneath as I already had the bash plates off (to clean all the mud out - thanks Chippy). And when I say dropped I mean it. Dropped the heavy bastard on my pinky. Even with gloves on still drew blood :evil:

    Chriso
    [COLOR=blue]Current rig - 150 GXL D4D Auto TJM bullbar. Airtec Snorkel. ARB Underbonnet Comp.
    Previous rig - 02 TD GXL.[/COLOR]

    Comment


    • #3
      Re: 120 KZ-TE Auto starter motor freshen up.

      Originally posted by Chriso57
      Ha Ha Ha Ha Ha Mitch,

      I bet I followed you through the same puddle the other weekend (the one right before our 1st stop at Harvey Dam).

      About 2 days later my starter did exactly what you described. Same thing cleaned the contacts with a file, back together with a file and sweet as. Starts better than it ever has.

      I dropped the starter from underneath as I already had the bash plates off (to clean all the mud out - thanks Chippy). And when I say dropped I mean it. Dropped the heavy bastard on my pinky. Even with gloves on still drew blood :evil:

      Chriso
      Nooo, not the Pinky!!

      Damn, that's the worst when you belt your fingers..
      [img]http://i49.photobucket.com/albums/f296/1cut808/MUMSRIG/Mitch-Prado.jpg[/img]

      Comment


      • #4
        Re: 120 KZ-TE Auto starter motor freshen up.

        Nice 'freshen up' Mitch. Just had to get mine sorted up the Cape (York) - too many creek crossings on the Overland Telegraph Track took their toll. When she finally died, it took us nearly 30 mins of gentle tapping with a hammer - the one that got her going was slightly less gentle (thanks Leachy :wink: ). Drove to the auto sparky (10 hrs without turning it off...glad the Prado has 180L tank). I got a big rebuild and cleaned up the contacts which were chunky and green, new bearings and new seals, so she should be able to swim safely again.

        Comment


        • #5
          Re: 120 KZ-TE Auto starter motor freshen up.

          Originally posted by fishnut
          Nice 'freshen up' Mitch. Just had to get mine sorted up the Cape (York) - too many creek crossings on the Overland Telegraph Track took their toll. When she finally died, it took us nearly 30 mins of gentle tapping with a hammer - the one that got her going was slightly less gentle (thanks Leachy :wink: ). Drove to the auto sparky (10 hrs without turning it off...glad the Prado has 180L tank). I got a big rebuild and cleaned up the contacts which were chunky and green, new bearings and new seals, so she should be able to swim safely again.
          It's certainly a pretty common excersize thats for sure Fishnut...

          I hope you enjoyed your trip even if it did involve a bit of a fixerup....
          [img]http://i49.photobucket.com/albums/f296/1cut808/MUMSRIG/Mitch-Prado.jpg[/img]

          Comment


          • #6
            Hey Mitch,
            I have discovered a similar problem, Intermittently the car refuses to turn over ,All I get is a click as your turn the key.( Battery's are good ) My guess is the solenoid is not making a clean contact .
            After several attempts it eventually starts.( and swear words)This only has started after going swimming at Dwellingup last trip.
            Looking at your solution might be my fix.
            When you say (Make sure you re-grease the solenoid plunger)
            Standard bearing grease is the go or do I need some of that white stuff.
            Any way ,I'll need do look at this soon as It is becoming more frequent.
            Thanks Russ
            2003 GXL Turbo Diesel,

            Comment


            • #7
              Originally posted by MUMSRIG View Post
              Hi all,

              Well... after the last couple of trips out and about MUMSRIG's starter motor had copped a bit of a soaking due to all of the mud trails and water crossings we have been through.

              The first hint was when Tam went to start and the starter motor kicked in and out then in again and soon after didn't want to kick over without a bit of a tap...

              The cost of a new one would be quite expensive (I'm guessing), so I popped the solenoid cover off the back and checked the contacts.. Sure enough they had the green meanies. Below are a few pics and steps to help you go through the process yourself to 'freshen up' the starter motor solenoid if it begins to play up. It will save you some decent coin and is only useful if the contacts are still serviceable.

              Tools required:
              10mm spanner (to disconnect the battery), 8mm short 1/4" drive socket and ratchet (preferably, although a ring spanned will do), long flat blade srewdriver, an extendable mirror, torch, emry paper (120 grit is fine) and a can of contact cleaner.

              The job can be done with the starter still fitted to the car. Solenoid is circled below...


              Firstly, disconnect the battery. Then undo the three 8mm headed bolts and using a flat blade srewdriver pop the cover off. Remove the solenoid plunger and be cautious of the spring as you could damage it if heavy handed.


              You can see the dirty contacts here..


              And here..


              Simply grab your emry paper and tear of a smallish piece and then contour your fingers into the solenoid to emry back the contacts a little bit. They won't need much work to get them cleaned up. Once your happy with the contacts then give them a good hit with the contact cleaner, this will also help clean out any mud etc that may be in there..

              Then run your emry over the the plunger contact until it resembles brass again. Mine still has some pitting but it's not that bad.


              Make sure you re-grease the solenoid plunger (not excessively) as the grease would have been contaminated by water etc over the years.

              Installation is reverse of the above, just be sure to line up the spring as you re-insert the plunger...

              And whalla, all going well you might get another 100,000 klm's out of it :P
              After going through a too deep bog hole about month ago, I drowned my car, got water in transmission (flushed 4 times same day then fully flushed the following weekend and seems good now), was up to my ankles in water in the cabin so had to rip seats out and stripped carpets out and hosed/washed then then hosed down inside (ruined the navigation and cd player probably but never used..so didn't put them back)

              Point of post is the starter motor is now just clicking and then then eventually turns over. Same symptoms as above :-( I was thinking relay or solenoid because once it turns is sounds healthy. Found your post tonight which I feel confirms cause and solution :-)

              I was wondering if you still had the pics available? I searched your photo bucket but dont see any starter motors.....

              thanks in advance
              Regards
              Mark

              Comment

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