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Thread: Intermittant starting issue

  1. 25th January 2018, 04:58 PM #1
    SavingTheDefender's Avatar
    SavingTheDefender
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    Intermittant starting issue

    Here's an odd one that I'm hoping that the brains trust can assist with.

    My '94 300tdi D'Fer occasionally fails to proceed. And after lots and lots and lots of new bits being thrown at it, I've finally now narrowed down the problem, but I am completely baffled as to where to go next.

    When I turn the key there is a single loud click. Before you go there, new ignition, new starter and solenoid, new earth cables, additional earth cables, new batteries ... if in doubt it's new including the under-dash relays. It's also not earthing via the handbrake cable, clutch etc.

    So in order to get it to start, what I have to do is roll it forward or backward slightly in gear and then release the clutch. This puts load/pressure on the engine/gearbox/flywheel etc and the vehicle abruptly stops with a jolt on it's compression. To give you an idea of how fast, it's not even close to being able to bump start. But it is enough to mesh the gears and everything else in place.

    Once this is done, I push the clutch in, then turn the key and it starts immediately every time.

    It's as if the little gear that the starter motor spins out to engage on the flywheel is getting stuck on something. The starter solenoid then clicks out under the load to stop the solenoid or starter from damage.

    I'm hoping that this makes sense. Has anyone had this happen before?

    Thanks in advance!
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  2. 26th January 2018, 03:24 PM #2
    workingonit
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    Is starter loose in bell housing? Have you pulled the starter motor and tested it with jumper leads from a battery to ensure fly out cog is not sticking a bit?

    With starter out, rotate clutch via crank nose bolt and check ring teeth; ring still uniformly in position and not off circumference; fly wheel still bolted securely?
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  3. 26th January 2018, 04:34 PM #3
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    rangieman
    rangieman is offline Swaggie
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    Teeth count ratio starter/m to ring gear
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  4. 26th January 2018, 05:20 PM #4
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    harro
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    Easy things first.
    as said check the starter motor, wouldn’t be the first dodgy replacement I’ve seen.

    Paul.
    Paul.

    77 series3 (sold)
    95 300Tdi Ute (sold)
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    I thought I was wrong once, but I was mistaken.
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  5. 26th January 2018, 05:59 PM #5
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    bee utey
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    There could be a chipped tooth on the ring gear of the flywheel. I'd investigate it carefully with the starter out.
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  6. 4th February 2018, 06:55 PM #6
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    SavingTheDefender
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    News just in ...

    Hi Peeps.

    So after few You-Tube videos and quite a bit of pondering, it looks like it might be some sort of intermittent open circuit issue to do with my winch controller.

    Power supply for my winch is off the starter +ve terminal rather than all the way back to the battery, which I understand is pretty normal for D'Fers.

    I've disconnected it for the moment and normal service has resumed.

    I'll post updates as more info comes to hand. But at this stage it starts first time every time.
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  7. 4th February 2018, 08:35 PM #7
    dazzler
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    Local Boy!

    Time to start a Hills AULRO chapter
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