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That’s not corrosion. That’s carbon. You can see the contacts didn’t make good surface contact like the other clean contact. The blackened contact had very little surface contact. That caused high current flowing through a small area of the full surface. The results were pitting and arcing causing carbon buildup. No signs of rust or internal corrosion show in the picture.
My observations after studying relay, switch and electrical connection failures working more than 30 years in the industry.
On Oct 21, 2020, at 11:58, Glenn Franco <brakey6666@...> wrote:
Our Navion/Sprinter has never seen salt even though I purchased in Michigan. The black on the battery terminal is caused by arcing across the two conductors.
In fact our Navion was never stored outdoors but always in an enclosed barn. The fiberglass finish on the coach sides does not show any weathering that causes the surfaces to dull.
Also I cut that solenoid apart on a lathe so those conductors are sealed from the outside elements.
Good luck on finding a replacement for your Valeo starter. Make sure when you search that you have the starter part number so you get the correct solenoid.
Google and Amazon are not trustworthy to get you the correct solenoid. Make sure in the part listing is shows your starter part number.
Glenn 06 23H 38600 mi
On Wed, Oct 21, 2020 at 10:06 AM Paul Rouis <prouis@...
Thanks Glenn and Bill. I had the intermittent issue and replaced the starter with a Valeo from Europarts.
I think it was about $200. Works perfectly after replacement.
I saved the old one and will see if I can follow your leads and rebuild it as a spare for $50 or so.
Thanks again for sharing your learning experience on the starter motor.
Do you have any idea what the road service use was on your rig?
One of the early 06 rigs I looked at for purchase was used extensively for hunting trips in the northeast displayed a lot of rust on the exposed metal undercarriage.
My rig has never seen snow or salt (except for some road ice in south Carolina one scary January day)
I'm just wondering what may have caused the copper to corrode.
The braided strap I removed and cleaned showed no evidence of corrosion. Im replacing it out of an abundance of caution and the fact that it costs $12 and is a 10 minute job to replace.
I'm not doubting your findings just sharing mine.
The only service fix for the starter is to replace it or the solenoid.
Solenoid if you can find one is less than $40 so that is my preferred fix. The starter motor is fine and should function with the new solenoid.
Make sure you pull the starter motor part number which is stamped on the main housing and match it up with what's available on eBay.
That's the only place I have been able to find one.
The photo I provided shows a solenoid that was cut at the crimp and their is no going back at that point.
Thx Glenn —
Great work — it should prove helpful to many owners! Would owners be able to ‘field service’ this - maybe clean up the contacts and apply a bit of dielectric? Do you have field service recommendations? Bill
[snip] "I pulled the old solenoid that failed with 32,000 miles on it and chucked it up in my metal lathe. I used a parting tool to cut off
the crimp that holds the plastic end cap with the terminals off to see if I could locate the problem.
What I found is that the copper strip and battery terminal contact is severely corroded and prevents the strip from providing any current to the motor terminal. That condition is what is causing the click of the solenoid but no
starter cranking or motor spinning.
See attached photos that show the condition.” [snip]