Rebuilding My Starter 1995 SL2 5-spd

[MINICooperS]

Need to rebuild my 1995 SL2 starter. As you can see from the pic, the brushes are gone after 15 years and 242,000 miles. Does anyone have a source for the brush mounting plate? The brushes are welded directly to the plate base. The car is going into storage so I don't want to put any more serious money into it. The solenoid, armature, and bearings are still useable. It's a 5-spd so at least I can bump start it, solo, after only 6' I might add.

[MINICooperS]

I think I hit pay dirt, at WAI. Looks like they have a Chinese division, but who knows. My original starter is stamped Made in Korea. Check this out, everything you ever wanted to know about Saturn SL starters. Now I just need to find a dealer.
FYI, the Valeo pictured in the document is slightly different than the Delco Remy.
http://www.wai-wetherill.com/techups/techup38_web.pdf
http://search.waiglobal.com/partsear...px?part=68-140
http://waicn.com/en/starterhousing/gb/prod.asp?m=30

[ssicarman]

Why not just get a used one from the newest lowest mileage S-series that you can find?

[MINICooperS]

Originally Posted by ssicarman

Why not just get a used one from the newest lowest mileage S-series that you can find?

Because unless I can see the brushes I would not be much further along, and I know my solenoid is good. I did find a source for brand new brushes so I'll probably go that route. Unless someone on this forum wants to sell me the brush plate?

[carfleet mntc]

Try Graingers.

[johnson94]

Would you have a picture of the wires that went to the saturn? i recently pulled the motor and wiring harness and a buddy messed up some of the wire ends. I know you have the feed from the alt and one from the battery, but how about the small wires? How many go to the starter?

[MINICooperS]

Originally Posted by johnson94

Would you have a picture of the wires that went to the saturn? i recently pulled the motor and wiring harness and a buddy messed up some of the wire ends. I know you have the feed from the alt and one from the battery, but how about the small wires? How many go to the starter?

Just one purple wire fastened to the 10mm wrench sized small center stud. It comes from the ignition switch starter relay circuit.

[MINICooperS]

Originally Posted by carfleet mntc

Try Graingers.

Good call.
They have a ton of brushes just not the ones I need.
I still don't get it, why Saturn starters go for 100 to 250 bucks, remanufactured???? And they used 7 different starters over 7 years!
Geez!

[alordofchaos]

Notes I grabbed from a previous starter rebuild thread:
http://www.saturnfans.com/forums/sho...ght=motorcycle

Most/all of the discussion below is DorisSL (Ben) and OldNuc

The rebuild is new brushes, solenoid, plastic gears, and pinion.

you get the parts from the BMW motorcycle parts place. http://www.euromotoelectrics.com/
The D6 starter is the one on the Saturn. Generally all you need is the brush kit unless the gaskets are dried out then you end up with the major kit. This is more of a disassemble, clean, inspect, and lube. Replace bushings and brushes

The Valeo D6RA series permanent magnet design starter has been known to be fragile to shock and vibration, as well as moisture (water ingress). These elements can cause the magnets to loose adhesion to the field can. Valeo addressed this issue in late 2002 with improved adhesive and thru modification of the magnet contour to allow more adhesive to be in between the magnet and the field housing.

http://www.euromotoelectrics.com/product_p/val-tk.htm
10.95 + shipping

Thats it or you can get the one with the 2 gaskets for another 10.00 I think. You need to herd up some synthetic EP-2 grease. My preferred product is Amsoil for the gearbox and bushings. There is no lube in the pinion clutch or the splines. A light dusting of the splines with either dry graphite or mica is OK thoough. If oil happens to get into the pinion clutch it will slip. Probably the hardest part is cleaning the armature and if it is out of round finding someone who knows how to properly turn it down. You do not undercut the mica on a starter. And you chuck it up on the bearing surfaces, not the old centers. With any luck the armature will be just fine and you can wipe it off with acetone and stuff it back in. Find a sheet of fine or extra fine real sand paper so you can bed the brushes. Do not use emery or aluminum oxide paper. Garnet paper is OK.

quick tip to anyone who decides to go this route - that seller also sells thru iOffer.com, which was cheaper for me.
buying directly through the link Oldnuc posted, they were going to charge me $10.95 for the kit and$10 for shipping, on iOffer, it was $12 for the part and $2.00 for shipping.

[MINICooperS]

Thanks for the info, good stuff if you have a Valeo starter. My starter isn't a Valeo but a Delco Remy (#21020761 used in 1994 and 1st half 1995) so I finally found a set of 4 brushes locally distributed by WAI for $7. Guess I'll go this route.

[2NDSOUT]

Originally Posted by MINICooperS

Thanks for the info, good stuff if you have a Valeo starter. My starter isn't a Valeo but a Delco Remy (#21020761 used in 1994 and 1st half 1995) so I finally found a set of 4 brushes locally distributed by WAI for $7. Guess I'll go this route.

Mini,

I got your email over the weekend. I have two dead starters. One is a Valeo and the other is an unmarked starter. I can take it apart for you and see what the plate looks like, etc. if you like; unless you are just going to stick with the WAI for $7.

Let me know.

Also, send me a pic of the lock mechanism for your 95 and let me know if you still need that.

[MINICooperS]

Will do 2NDSOUT,
If anyone else decides to go this route the WAI part numbers are:
BRH-113 or 69-113 for the brush holder assembly or
68-140 for the individual brushes.
The prices are all over the map from $7 to $30 depending on the distributor.

Again, this is only for the Delco Remy starter used on 1994 and 1st half 1995 Saturns.

[MINICooperS]

Something old, something new. Thought I'd post pics of the new starter brush assembly compared with the old one, for future reference. The new assembly from WAI comes pre-loaded with new springs.
Enjoy!

[MINICooperS]

Finished.
Note: If you are good with your hands, like on your first date, you can remove the top starter bolt from underneath by "feel" alone.