Starter motor not turning over (broken wire I think)

[buzzsaw]

Can't get the starter motor to turn, altough the solenoid is clicking.

Just had a look under the car and found that one of the heavy duty positive feeds (thick red wire) is not connected to anything. There appear to be two feeds, one coming from the engine bay, through a fuse, which seems to be connected OK, and the other looks like it is coming from the area of the battery/fuse box, which is now not connected to anything!

Two questions:-

1) Where is this wire meant to be connected (any photos would be great)
2) What is the best way of reconnecting, assuming that the spade terminal has corroded off?

Thanks in advance.

[spend]

Sorry, I can't really visualize what you are describing. When you say thick red wire, do you mean battery cable?

Dave

[buzzsaw]

Its most likely coming directly from the battery, but haven't followed it back all the way yet. Its cable tied to the chassis rail.

[spend]

They all have a big red battery cable that goes directly from the battery to the starter motor - is that one connected?

Dave
ETA: FFS disconnect the battery before playing with that one - you will be welding otherwise

Edited by spend on Saturday 20th October 14:22

[buzzsaw]

No. Thats the one that has decided to liberate itself form the starter! Where is it meant to attach?

[spend]

There is a terminal stud on the starter with a lock washer and nut (presumably they have gone AWOL also.

Commonly a couple of brown wires share the same stud and go off to the pesky fuse (but there are a couple of variations..)

Dave

[buzzsaw]

So are you saying that I can connect the main battery feed to the same terminal as these?

Thanks for your help.

[GreenV8S]

I'd reinforce the comment made earlier: FFS isolate the battery right now or you could have the whole thing on fire before you know it.

With that out of the way:

How thick is this wire that is not connected to anything, is there any sort of terminal on the end?

Edited by GreenV8S on Saturday 20th October 14:45

[spend]

Yes, There is a stud on the starter which has battery cable on all cars I have ever seen - its the biggest power draw in the car (unless you have some kind of electric car ).

I would check if you actually have the stud & ring term still on the starter - it may be that the cable has come out of the crimp. Those big cables / terminals are quite hard to crimp - you may need help from an auto-electrician.

Typically it draws well over 200A for the starter, so there is no protection - be very careful with it! If it has fallen off I am very surprised you have not had a short against the chassis / engine already.

Dave

[buzzsaw]

OK, I have disconnected the battery (the battery lead has an insulating sleeve on it, hence no shorting to the chassis), but I can't see where it is meant to attach to. It looks like it has broken off but I can't see where from. There only appears to be one connection to the starter itself, which is coming off the solenoid.

Does the battery lead connect to the solenoid, or directly to the starter? Photo/diagram would be much appreciated.

Thanks


ETA: GreenV8S, Its definitely the battery lead (thick red cable). Looks like there might have been a terminal on it at one point.

Edited by buzzsaw on Sunday 21st October 13:31

[spend]

Yes the stud is on the back of the solenoid part of the starter, there is also teh spade terminal (which must be connected - its working ). The 'built in' lead that goes from the solenoid to starter is an integral part of the starter/solenoid unit.

Dave

[buzzsaw]

Thanks Dave.

Looks like I'll need to get down to Halfords for a crimp kit!

[GreenV8S]

If the terminal has pulled off the end of the cable then you should find it still attached to the solenoid. It may be that the terminal itself has broken, in which case you'd have the ring attached to the solenoid and the crimped section still attached to the cable. I suggest you cut that sleeving back and see what's left. Remember that you will need to insulate the end of the cable afterwards, you can get heat shrink sleeving for the purpose, or just use lots and lots and lots of insulating tape. (You *really* don't want this cable shorting against anything.)

[spend]

I don't think Halfords sell big terminals - I'm not even sure they sell any un-insulated terminals. The crimpers for these big terms are quite expensive BTW..

Have a look at the VWP website, it may give you a better idea of what is needed. Finding a local auto-elec who has the kit and will come out & do it in-situ is probably your best bet I would have thought.

Dave

[buzzsaw]

Any idea what cross section the battery cable is (16mm2?). I am trying to identify the correct crimping tool to attach the terminal.

Thanks

[spend]

Measure the diameter, I wouldn't bank on all cable being the same. I replaced my 25mm2 with 40mm2 for instance.

Dave