Hi there
Got a 2002 TD5 110 CSW. Last few weeks been having intermittent trouble starting the tub... turning the key gives the relay click, but starter motor didn't turn over. Checked battery, cleaned up starter motor terminals which seemed to help, but didn't totally fix it, maybe 1/20 times the problem re-occurs.

Decided to refurbish the starter motor solenoid with new contacts etc, so spent a few hours taking it off today. Was quite dirty and corroded inside, so gave a good spray with contact cleaner, fitted the new parts... had high hopes that the refurb would give good results. Starter motor seemed to bolt back on OK.

Silly me... I've managed to make it 100 times worse. Half the time now I get the relay click but no starter motor turn over. Sometimes it will turn over, but makes a very rough noise doing so and doesn't fire. Managed to get it running once after rocking the tub from side to side and turning over for 10s.

What do you reckon.. new starter motor?

Cheers
SMG

Just buy a new starter, there not exactly expensive, I bought a AAP one for my old disco and it was perfect

Get a new one, could be corrosion in the motor itself.

Could be the contacts have twisted when tightening the wires to the bolts. This is what happened to mine, leaving me with similar issues. Had to rebuild, and ensure contacts tight before connecting the wires outside.
Good luck
Ken

If you decide to buy a new one, i would recommend a refurbished original Bosch instead of the new copy chinese offerings...

Refurbing a solenoid is a bit ambitious considering how much they cost, I know they arnt cheap but sticking a new starter on there will be done with it. You could pull the starter apart and see what its like inside, chances are cleaning it out will get you out of a hole. Check for a weak battery too, a weak battery will destroy a starter solenoid.

Just a thought, re reading your original post, was it starting lazy all the time or was this just a 1 in 20 thing but normal the rest of the time?

Hi Nobber, timeline was sort of

3 week ago) Fired on the button every time
2 weeks ago) Relay clicked, starter didn't turn over unless I rocked the tub... when it did decide to turn it fired on the button. Battery looked good at 12.6V, cleaned up all the external contacts.
Since then (well, until I broke it) she's been starting on the button, apart from maybe 1 in 20 times when relay clicks but no turn over.

Bought a nice new shiny Denso starter motor this morning.... to put on when it stops raining.

Cheers

Simon

New starter motor sorted it. Starts on the button again.