For starters...
Went by the local vatozone and seen a starter rebuild kit. That got ne thinkin... jeez, id hate to pull the damn starter anytime soon. I wonder if its worth it to check it out.
Sure enough, when i opened it up i could see that the contacts were going bad. The darn thing still worked, but i knew it could be a problem in a matter of months not years.
So... we rebuilt it.
First we tried to find a replacement plunger. Their available online, but not locally. I seen the copper contact disc is still thick, so it got emory cloth to smooth out the pits and lines.
The armature got a cleanup on the contact too.
I also cleaned up the housing, bearings, drive assembly, and made sure all moving parts moved freely.
Next i wire brushed the 2 copper bolts and leads we were reusing
All we had left were the plunger contacts to replace which came with the rebuild kit
We made sure the contact ends laid flat in the housing to prevent premature fails.
It didnt take long and was easy enough.
I am impressed by the ministarter and would recommend anyone to use one instead of the behemouth starter which comes stock.
The starter cable is too short now. I am going to have to fab up an extension later.
Meanwhile i rerouted the harness a final time.
I went behind the a/c airbox and avoided the exhaust a bit better than before.
Ill need some heat shield tape and it should be fine.
What didnt look good was my washer bottle. I went ahead and replaced it now while the access was available.
All i need now is to solve the starter cable problem, install the new detent cable, and install the transmission dipstick tube to be done with this troublesome episode... that is till i have to connect the exhaust lol!
Later!