2006 S60 2.5T starting issues...

[Krons]

Most ppl simply buy a "new" starter bc it is easier that way...

Maybe I’m a high roller but for $150US and lifetime warranty I’d rather go the remanufactured route. In my mind it seemed less cost/time overall.

[vtl]

New starter is $85 or so.

[br0dy519]

cn90, always looking for the next project... LOL Can't wait for retirement!!

[cn90]

I just looked at the Bosch starter motor for P80, P2 (up to 2006 or so), Bosch SR0483X...

- The Bosch starter Bendix PN is 1 006 209 677.
- It is the common type with 9 teeth.
- In Europe, it is about 12-15 Euros or so.
- If anyone finds this in the US or Canada, please post.

PS: I think around 2007, the starter is probably similar with the only difference being the spade terminal
(spade terminal used until 2006 and maybe some 2007 starter???). The 2007 and later starter uses
eyelet terminal that you need to use a nut to hold it in place. Otherwise, the 1994-2006 starter looks
similar to 2007--->.

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Bosch-Starter-Bendix.jpg (91.65 KiB) Viewed 408 times

[cn90]

According to the YouTube video below, inside the solenoid, there are 2 separate components:

1. Pull-in coil: this provides electricity to the motor itself, spinning it.

2. Hold-in coil: this moves the arm for the Bendix to engage the flywheel.

So, if #2 fails, all you have is a spinning motor and the flywheel does not rotate at all...

[cn90]

Sorry,

Forgot to update forum, it is now 2.5 yrs later, I have some time today to update you guys about
this interesting issue lol...

- The root cause of the 2006 S60 was: the starter motor (probably from O'Reilly) ---> the teeth
were all chewed up!!! I checked the flywheel: all flywheel teeth are in perfect shape!
So the flywheel teeth are hardened metal. The starter teeth are made from softer metal: sacrificial.

- Good thing the problem was bas starter motor teeth and nothing major.
The flywheel teeth is a BIG job...luckily this was not the problem.

- All is good with "new" starter from junk yard.

- Does anyone know why the starter teeth are all chewed up? I searched the internet and of course
this has happened before in many cars (even in Porsche), but it is a rare problem.

- FYI Volvo Trivia: the transition of design of starter is between 2001-2006 vs 2007-2009.
Wonder why they changed the solenoid wiring (butt vs bolt connector) and 9 teeth vs 10 teeth,
same flywheel for all these years (I assume) but why changed from 9 teeth to 10 teeth?

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S60-Starter-01.jpg (176.46 KiB) Viewed 151 times

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S60-Starter-02.jpg (156.33 KiB) Viewed 151 times

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S60-Starter-03.jpg (159.94 KiB) Viewed 151 times

[vtl]

Sorry,

Forgot to update forum, it is now 2.5 yrs later, I have some time today to update you guys about
this interesting issue lol...

- The root cause of the 2006 S60 was: the starter motor (probably from O'Reilly) ---> the teeth
were all chewed up!!! I checked the flywheel: all flywheel teeth are in perfect shape!
So the flywheel teeth are hardened metal. The starter teeth are made from softer metal: sacrificial.

- Good thing the problem was bas starter motor teeth and nothing major.
The flywheel teeth is a BIG job...luckily this was not the problem.

- All is good with "new" starter from junk yard.

- Does anyone know why the starter teeth are all chewed up? I searched the internet and of course
this has happened before in many cars (even in Porsche), but it is a rare problem.

- FYI Volvo Trivia: the transition of design of starter is between 2001-2006 vs 2007-2009.
Wonder why they changed the solenoid wiring (bolt vs butt connector) and 9 teeth vs 10 teeth,
same flywheel for all these years (I assume) but why changed from 9 teeth to 10 teeth?

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S60-Starter-01.jpg

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S60-Starter-02.jpg

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S60-Starter-03.jpg

Pretty sure the starter in my 02 V70 had a butt connector. It was in fact a culprit why the starter didn't want to work: bad oxidation in contact pair.

[cn90]

@vtl,

You are correct...

I just edited my post above: early years ---> butt connector; later years ---> bolt connector.

[vtl]

@vtl,

You are correct...

I just edited my post above: early years ---> butt connector; later years ---> bolt connector.

So the answer is clear: butt connector oxidation is a plague with these older starters. At least where it is located in Volvo. Bosch improved it and converted to a more reliable connection method.