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Alternator Wire back to starter- Too Thick for starter stud?
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vanagon_fan_again
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Joined: October 20, 2009
Posts: 157
Location: Paoli, Indiana
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PostPosted: Thu Mar 10, 2011 11:01 am    Post subject: Alternator Wire back to starter- Too Thick for starter stud? Reply with quote

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. Embarassed 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. Rolling Eyes

I'm just assuming everyone has the same thick alternator return connector, if not-
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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.
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1989 Vanagon GL 2.1 Automatic. Metallic Blueeee.
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dhaavers
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Joined: March 19, 2010
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Location: NE MN (tinyurl.com/dhaaverslocation)
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PostPosted: Thu Mar 10, 2011 11:08 am    Post subject: Reply with quote

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!
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PDXWesty
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PostPosted: Thu Mar 10, 2011 11:28 am    Post subject: Reply with quote

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.
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danfromsyr
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Location: Syracuse, NY
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PostPosted: Thu Mar 10, 2011 11:29 am    Post subject: Reply with quote

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.
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