Solenoid won't engage; I see small spark and smoke puff

[sshanky]

Hi,

I recently had some problems with the terminal that connects to the top of the solenoid (the one that engages the solenoid) being loose. It is super difficult to reach to put on tightly! My brother got down underneath the car and guided the terminal to the spade on top of the solenoid. There was no way he could get his fingers close enough to push it on with enough pressure, but I took a straightened coat hanger and, from the top, through an opening in the manifold, used it to push the connector onto the terminal. it worked fine for a few weeks.

The other night, it didn't start. I reached underneath and moved the wire and it started. I took a chance and drove somewhere nearby. But I couldn't start it to go home, no matter what. I looked in through the opening in the manifold, where I can see the place where the terminal is, and when someone else turned the key, I witnessed a small spark and puff of smoke come up from the solder joint just in front of where the wire attaches to the terminal -- it seems that the solder joint is where the wire goes into the solenoid.

Any ideas? Do I need a new solenoid? I hope not!!!

[azruss]

sounds like you got the connector jammed between the spade the solenoid body. It stayed there until it finally wiggled loose. sounds like your retry is doing the same thing. arcing against the casing and burning something nearby.

[sshanky]

I was wondering if that is it, too, but I see the spark and smoke clearly coming from a different spot, about 1/2" ahead of the spade connector (toward the back of the car). I see a solder joint which appears to be the place where, from below it, the wire would lead into the solenoid.

[azruss]

there is a small, very short wire that runs from the solenoid to the field windings. If that is broken and arcing, you have a big problem. I've never been able to repair that wire without screwing up the windings. On most starters that is at the front where the big lugs are, not in the back where the spade connector is. Either way, looks like you will need to pull the starter to see what you've got.

[So Cal Mark]

or, you could tighten the nut that holds the wires to the solenoid