Starter motor stuck on

[chilla]

TD5 210,000km.

Hey guys hope all is well,

Over the past few weeks, I've noticed when I try and start the Disco, I can hear a click (from the starter motor I assume), and the engine doesn't crank. So I turn off ignition and back on and she starts. Yesterday it clicked three times, on the 4th she started. I Went inside while it warmed up and upon return I heard a high pitched whine. Couldn't tell where it was coming from, so I went to turn off engine. Instead of shutting down completely, when I turned the key to off, she kept trying to crank. So i turned key back to on and she fired up. Turned key back off and same thing, she kept trying to crank. So instead of leaving it cranking, I turned key back on to get engine idling. I disconnected battery and when I turned key back to off, she finally shutdown. Bit of smoke coming from engine bay, I'm assuming the solenoid is getting continuous power and is frying. So maybe a relay welded shut which would supply constant power. Hopefully that and not the $tarter itself. I just got back home from work, so going out to check it now. In the meantime, any info would be appreciated. Thanks boys.

[Graeme]

Burnt solenoid contacts? If it's a TD5 then the solenoid contacts are replaceable.

[chilla]

Yes it is a TD5 with 210,000km.
As it turns out, it seems like the contacts inside the starter solenoid are getting stuck together. I know this because when I went out to start it and it kept trying to turn over once I tried to shut it down, I once again d/c battery and turned ignition off, which successfully shut it down. I took off the permanent power to the solenoid from the battery and then reconnected battery. There was no power on the positive to the solenoid coil from the 30A relay (which is good as power should only be there when you turn the ignition key to start) but when i touched the main positive back onto the solenoid contact, she tried to fire. I took it off quickly and touched it again. The 3rd time must've freed up the contact because I was able to bolt up the main positive without it trying to start. Once I did this, she started and stopped correctly 20 times or so. So she's working again fine, for how long, who knows? Doesn't fill me with confidence. Anyone knows how much a new starter roughly is? And if it's a lot cheaper, am I better of buying and replacing the internal contact inside the starter solenoid? If anyone knows a rough price and best place to buy either the contact or starter, I'd appreciate the info. Thanks.

[Graeme]

I understand that the starter's solenoid contacts are normal stock at lots of auto-electricians because they're used on various much more popular vehicles.

[chilla]

Thanks, I'll check it out

[schuy1]

Starter motor is Nippondenso brand, very common and standard fare for many types of vehicles so parts are not a problem.

[kelvo]

The plunger spring could also be broken.

Using a 8mm spanner you can remove the solenoid cover and remove the plunger to check. Make sure you disconnect the battery before removing the cover.

[fourteen8]

I bought this kit off ebay.

https://www.ebay.com.au/itm/251459778483

I am not sure if you can wait around 2 weeks for the parts from uk.

[chilla]

Cheers boys got it sorted. I had the starter off pretty quickly, just put the 15mm socket on the 6inch extension, then felt my way and put it on the nut. (Bottom two bolts don't need explanation). Attached the ratchet and used a small pipe I had over the ratchet, to crack the nut, ratchet away and done. Re-tightening was harder, anyone know how man nm or ft lb the top nut should be?

[sierrafery]

It should be 27 Nm (20 lbf.ft) but IMO you can live without putting it back... mine was binned two years ago and no probs

[chilla]

Binned as in thrown in the bin? So just the bottom two bolts holding the SM in for two years and she's all good?

[sierrafery]

Binned as in thrown in the bin? So just the bottom two bolts holding the SM in for two years and she's all good?
Yes

[kelvo]

Not many corrugations in Europe though ;)

[chilla]

Yeah I just re-read this and noticed it could be misinterpreted. I managed to get both bolts and the nut on easy enough. Tightening of the nut to the correct torque was challenging. There's no way I'd leave the starter on with only two bolts.
Anyone know what the drain pipes out of the motor and solenoid are for? Seems to let muddy water IN to a sealed unit?