Greg,

Replace the Starter.
My wifes 240D was doing the same thing.
Replaced the starter Problem solved.
You can replace the solenoid but when I took the old
one apart to inspect it before I did the solenoid change
the Brush holder was messed up and the commutator came out
in 3 pieces.
Save yourself sometime and order one from Rusty.

Russ W. Still looking for a Manny Tranny Grrrrrrrr
240D x2

Greg Fiorentino wrote:
Hi All:

The son's 240D has been experiencing minor difficulty starting for a while
(grinding a bit, then starting), culminating in a no start condition.  I
checked the battery, it is showing 12.5 volts and headlights come on bright.
I tried jumping from the wife's TD, showing 13.75 volts at the 240D battery
(with TD engine running).  No go.  I tried tapping the solenoid with a
mallet (maybe not hard enough).  Still no joy.  It is cranking very slowly
and grinding.

My hypothesis is a sticking solenoid.

I have the 123 manual CDs, but don't find any module on R&R the starter.  I
see Rusty has a rebuilt Bosch for a good price.  I have searched the
archives and found a few messages saying this is a pretty doable repair.

Am I overlooking something in the manual?

Any tips or tricks?

TIA

Greg Fiorentino
'85 300SD
'80 240D 4 spd. manual
'79 300DT (with new crate engine)
'95 and '97 Crown Vics







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