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Starter stuck ON, looking for clarification

4.9K views 6 replies 3 participants last post by  stylin7  
#1 ·
About 2 months ago, I replace the starter contacts on my 97 with the LarryB's super size starter solenoid contacts. Now this morning, my starter stuck on and had to disconnect the batteries. From what I have found the starter will need to be rebuilt, but not sure which parts since I just installed the solenoid contacts not long ago. I also understand that the shut-down solenoid my need to be replaced, but I can't know for sure until starter issue is solved.

Any links to the starter rebuild process would be great as well as what else to look at for causing the starter to be stuck on.
 
#2 ·
Don't discount that the contacts are still good.
Low voltage starts caused by bad connections or old batteries can wear out contacts rapidly.

Also check that the problem is electrical rather than mechanical by unplugging the shutdown solenoid when the engine runs on.
Could be a binding linkage or solenoid.
 
#3 · (Edited)
Took the starter solenoid apart to look at the contacts. Here is what they look like.

The starter solenoid plunger was fused to one or both of the constants.

With the batteries disconnected the shut down solenoid linkage is easy to move by hand.

I am lost as to what to look at next.
 
#4 ·
Looks like something was installed cockeyed or the plunger was defective and there wasn't even contact between the plunger and contacts.
Made it so all the juice was trying to flow though a small area and welded the plunger and contacts together.
 
#5 ·
x2, the contacts were not installed straight causing the contact point to be limited to a vary small space on each one. This causes alot of excess heat and arcing which eventually resulted in the "welding" of The pieces

Get some new contacts and be sure to install them straight!
 
#7 ·
Looks like I got lucky.
Went to Napa to pick up a new fusible to verify if I need a shut off solenoid. Installed the link and reinstalled the starter solenoid contacts so they are flat and making proper contact. The old beast started right up.

Thanks for the help. I am going to keep a close eye on things and any signs of not being 100% and new parts are getting ordered.