Thread: TD5 Starter rebuild

You don't even need to go to eBay for one. Any good auto electrical place will have a kit for it. It's a Denso starter so common as muck.
I got mine even cheaper than that from Ashdowns.

Search the Good Oil for changing it. You WILL need a 15mm 12pt socket and a 3/8 drive extension of about 150mm length or there abouts.
Top nut is the ****** and this is why you need the above items but once you have a feel, it comes off a breeze.

Andrew

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- Using Capitals, the difference between helping your Uncle Jack off a horse or helping your uncle jack off a horse...

Rebuilding the starter motor is no big thing, getting the starter in & out is a pig though. Make sure you have a good supply of 3/8” wobble extensions, unijoints, flexjoints, etc.

Based on a recent job this would be the DIY procedure.

First off give the starter a good clean up and set up the operating table (8, 10, 11, 12, 13, 14 & 15 mm wrenches, degreaser, rag, etc.)



Remove (3) x 8 mm hex screws and take out solenoid housing cover plate:


Solenoid plunger at sight:


Pull plunger & spring out:


How the contacts looked:


How the copper contact in the plunger looked, this bit is pressed against both contacts to close the circuit and power the starter:


Carefully undo the nuts and break apart both contact assemblies (back up from inside with appropriate wrenches):


How it looked with the contacts out of the way:


The contacts as they came out (the RH one is presumably a non original one – starter had been repaired before):


Repair kit:


New vs used contact, note the amount and shape of wear:


Used (left) vs new (right) plunger, again note how much material has been lost:


New contacts just installed:


It is worth doing some continuity tests with a multimeter or tester as to make sure everything stayed as it should be. In the above picture:

- The left hand contact is common to ground so should have continuity against the housing.
- The right hand contact should only conduct to the external contact bolt where the battery positive connects.
- The external Lucar connector (spade) should only conduct to the lower right end conductor going down into the solenoid coil.

Finally push the new plunger (with old spring) in and reinstall the housing cover plate. Starter is now as good as new!

Cheers
Matt

Thanks Matt that it a cool tute.

Predo can you link to the Good oil on this one?

Does anyone have a part number for the repair kit? is the RLK53528 as per the Ebay add a landrover number or is that the one for the sparky as well?

Thanks again Matt those photos are so help full.

Cheers

Mattg

LR doesn't provide the repair kit per se, but does sell the entire solenoid & housing which is p/n NAF500010




As for the OEM (Denso) parts for this job, have some but not all:

053660-7241
Contact & Plunger Assembly

053513-0241
Contact

Have always sourced the kits from eBay without a hassle.

Cheers
Matt

Originally Posted by mturri

LR doesn't provide the repair kit per se, but does sell the entire solenoid & housing which is p/n NAF500010

As for the OEM (Denso) parts for this job, have some but not all:

053660-7241
Contact & Plunger Assembly

053513-0241
Contact

Have always sourced the kits from eBay without a hassle.

Cheers
Matt

OEX part numbers from Ashdowns

Contact set- SLX75827
Plunger - SLX75564

Don't break the spring, doesn't come in the contact set and can only be bought with a complete starter motor rebuild kit.

I was lucky, part of my problem was actually due to the spring disintegrating and my contact at Ashdowns actually had a robbed full rebuild kit with the spring still in it.

Well I have my new plunger and contact and the car wouldn' start again today so i am into it tomorrow.

It sounds like the worst part is getting the starter out of the car.

I haven't had a go but is it possible to take the cover plate off and get to the plunger and contacts while the starter is still on the car?

Cheers

Matt

Originally Posted by mattg

Well I have my new plunger and contact and the car wouldn' start again today so i am into it tomorrow.

It sounds like the worst part is getting the starter out of the car.

I haven't had a go but is it possible to take the cover plate off and get to the plunger and contacts while the starter is still on the car?

Cheers

Matt

When I did mine I didn't think it could be done with out removing the starter.
However on a thread a few weeks ago it apears some members have done the plunger/contacts with the starter fitted.

I Can get my socket on that Nut but there is no way I can get enought leverage through the uni to get it undone. I have looked for the posting on doint the plunger while it is in the car. but can't find it, does anyone know where that might be hiding?

Thanks

matt