Starter Motor problems.

I have been reading the web articles about starter motor problems and found a major problem which I think everyone has over looked.
Some members have written about voltage drop to the starter motor and complained that the original starter relay fitted to the P76 is inadequate. This is NOT the case. The problem with the system is in the wiring. The Starter relay uses a 2.5 mm wire for the battery supply to the starter relay. This wire then runs up the harness and goes half way around the world and then comes back to the fuse box where it is attached to the main 5.5 mm thick brown battery feed wire.
To fix the problem you have to open up the harness at the fire wall just next to the fuse box where the wiring runs down to the starter relay and the inhibitor switch Then join the thin 2.5 mm brown wire to the thick 5.5 mm brown wire.
This will fix the voltage drop problems to the starter relay. Hope this helps. Garth

---

On earlier models where the starter solenoid relay is mounted vertically on either the left hand or right hand Valance, it has been found that dust and moisture can enter the relay box & cause a short circuit thus energising the starter. MODIFICATIONS: Remove the solenoid relay and remount it horizontally. To overcome problems of starter pinion meshing with ring gears fitted to all versions of automatic and manual transmission models, it has been necessary to fit special pinion drive end brackets which were machined to provide an offset of .025" at the register, This offset has been termed "eccentric" enabling the pinion to be moved closer to the ring gear. A larger ring gear and concentric starter motor pinion drive end bracket has been fitted to all automatic transmission models and the manual transmission models of the E6. The V8 manual models have not yet been changed. Dealers will be notified when the change is introduced. A large triangle has been etched on the outer surface of the pinion drive end bracket adjacent to the solenoid mounting. The concentric type is unidentified. The charts following (next page) show the commencing engine numbers applicable to the changes and the associated part numbers. The I.D. of the oversize ring gear used with the concentric pinion drive end starter bracket is unchanged and can be fitted to any flywheel. Cases have been reported where the solenoid Bakelite cover has overheated due to internal arcing. In some instances the heat has been conducted along the 3mm solenoid coil wires, melting the insulation. Investigation into the problem has revealed that water is entering the solenoid when the vehicle is operating in extremely wet or flooded conditions via the Bakelite cover joint and at the terminals. A sealing operation has commenced in production at the following engine numbers: P76 - F6 - 26004028 2601-2964 2603-1927 P76 - VS - 4400-5811 4401-2199 4402-2138 4404-2574 4406-1010 4407-1001 4408-1152 4409-1014 4410-1001 4412-1364 4413-1004 4414-1001 A satisfactory sealing operation can be carried out in the field by adopting the following procedure: - 1). Protect the top end of the Lucar blades and the threaded terminals with plastic tubing or tape 2). Apply masking tape around the body of the solenoid approx.1-2mm below the joint with the cover 3). Brush apply 3m "Duct Sealer" to seal the Bakelite cover and adjacent portion of the body, ensuring a heavy application of sealer at the cover to body joint and at the base of the Lucar and threaded terminals, particularly behind the hexagon nuts & securing screws. 4)Remove the masking tape and plastic tubing 5). Allow to dry I hour before assembly. If it is suspected that a solenoid has already suffered water ingress the solenoid should be dismantled & the switchgear cleaned prior to carrying out the above sealing operation. Alternatively the solenoid should be replaced with a new one if any severe burning is evident the new solenoid should be sealed before fitting to the vehicle