TheSamba.com :: View topic - Alternator Wire back to starter- Too Thick for starter stud?

Thu Mar 10, 2011 11:01 am

If any of you have been following my ongoing starter problem threads- Found the sum of all my problems. A self tapping screw I foolishly used on my floor went into the red/black wire that tells the starter to start. :oops: Was hard to find, but I'm sure thats what has given me so much trouble.

Anyways- Got a new starter today, took the last warrantied one in because I'm fairly sure the solenoid wasnt working. New ones pretty much the same but different- The stud for the batt cable/alt wire is a good bit shorter. :roll:

I'm just assuming everyone has the same thick alternator return connector, if not-

Now my question is- Would it be alright to cut this large connector off and put a simple flat one on? Or would that mess up the charging circuit? I really dont want to take another starter back to the FLAPS for the 3rd time, but if it has to have that special end on it I guess thats what I'll have to do.

Thu Mar 10, 2011 11:08 am

Your electrical connection comes on the mating surfaces of the connector, so you don't need that thick old thing.
Cut it, crimp & solder the "flatter" replacement & get on with it...

Happy Trails!

Thu Mar 10, 2011 11:28 am

The mass of the connector also absorbs heat though. I'm wondering if for some reason that is needed on that particular connection. It's at a point where you are getting a very high amperage distributed to the entire vehicle. A smaller connection will heat up more. Just a thought.

Thu Mar 10, 2011 11:29 am

Indeed that's a wiring upgrade for 85+ (?) Vanagons
I clipped our and soldered/crimped a heavy Ring terminal (any FLAPS/Marine store) to make that connection when I switched mom's Automatic starter($150) for a 76-79 bay automatic starter ($50) with the shorter solenoid stud.

*note 76-79 Bay AT starters are LONGER (+more hp)then a vanagon and some adjustment of the throttle rod/kickdown rod was necessary to reach around the new motor.
$50 Bay AT starters are available via NAPA & Pepboys.