Well guys i thought i would update everyone on my progress. Its long and boring so be warned
So 2 weeks ago, i pulled the starter out because the truck was crankin really slow, but i didnt have a big voltage drop at the battery. I had issues 2 years ago with the starter when i first got the truck, you had to click it a few times before the starter would turn on. That issue went away and didnt haunt me untill after our outing this spring.
So out it came to investigate, and i found out the problem. As many of us know our starters are waterproof "somewhat" and for anyone whos seen the starter solenoid in person knows that it has a removeable back contact plate that the copper disk inside makes contact with to start the starter, this solenoid also engages the bendix onto the flywheel even before the starter begins to turn over. Now this back contact plate has a rubber gasket around the outside to keep water out. Well after 10 years of aging, and with it being extremely close to the exhaust manifold, the rubber on the top of the solenoid get brittle and can let water in. Now the problem isnt the fact that water can get in, its actually that the water cant get out once in because the lower half of the gasket is still good, and the water spends lots of time chewing away at your coil windings, solenoid shaft, and contacts.
So with the starter out, i cleaned up the solenoid as best as i could. Also with the starter out i pulled the back cover on the motor to see how things were looking, the motor was bone dry inside, and the brushes and armature looked great. Theres also 3 small spacer washers that are on the end of the motor shaft, which unknown to me in the following week; cause me much headaches. I put it back together and after wrestling with it for a good portion of the day, busted and brused hands, tired arms; i got it back in the truck. I also cleaned all my batt contacts and put some new bolts on, turned the key, truck started soo fast i had never seen before.
So fast fwd 3 days later, thankfully this day i wasnt at my usual work location, my work has a head office just 3 min at home and i was there that day for a training seminar. Go outside turn the key, and i get 1/2 a solenoid kick then dead. @*!(@)!!! Power to everything, just no response from the starter !@&@*!!!...... !)*!&%!##!!! My dad drove over with is pickup and we towed my truck home... Just barely, the roads were slick, and he barely made it up one of the hills with the tires spinnin
And note to anyone, the hydroboost resereve only gives you about 3 moderately forcefull assisted brake pumps before your on your own.
Next day tear the starter out, and do a once over, everything looks good, pull the back cover off, check the motor and it looks like the starter brushes are stitting at just a slight angle to pervent good contact (the solenoid is a 2 stage style that has 2 internal feed leads to alter pull force depending on the starting cycle, and one of them relies on a good power contact path on the motors + feed side; if that makes any sense). Then i notice that the washers are missing, did it eat them up? theres no way i forgot to put them in, i never forget!
So i tear apart the shop looking for these 3 washers, no where to be found. Then out of no where they appeared, sitting on the hot tub cover in the backyard
Because the starter install can be a serious PITA! by yourself, i said midas well do it right so i dont have to take it out agian. So i overnighted 2 solenoids from the US, one for a spare. And got the starter all buttoned up, and the truck starts better then it ever did.
With this downtime, i also began finishing up my rear racks, and finishing fab on my winch mount. I should have it all installed tonight and back on the road tomorow
Its a long story over a boring starter, but i cant wait to start driving my truck agian. A week without it gives me new appreciation for it