My mechanic called me today after doing some maintenance and transmission service and told me that the starter case (the Bendix side) is melted from the heat coming off of my exhaust manifold. He was surprised I was still able to start the coach - he is going to replace the starter and fabricate some sort of heat shield to protect it.
Has this ever happened to anybody - seems like a poor design or perhaps a heat shield was missing, if there ever was one. I'll attach photos next week. I have a 400 ISL.
Pat
Just curious if this has happened to anybody.
Thanks
Pat,
Has the mechanic checked to see if there is a crack in the exhaust manifold? Sure sounds like there is some place that is leaking hot exhaust gas which would be like a blow torch.
Mike
Thanks - I will ask them today - good info.
Pat
A quick search of the Forum archives does not turn up any hits on this particular failure. We have had lots of melted battery terminals, sparking connections at the starter, and totally dead starters.......but I don't find any MELTED starters. :o
Pat,
Any black soot in the area might indicate a blown head to manifold gasket. This is fairly common and a pretty easy fix if the manifold cooperates. On the other hand, it's also common to have a crack in the exhaust manifold.
What is this? ...and my other car is a Seagrave A fire truck?
Pierce
Hi, thanks, yep I'm a firefighter in Los Angeles and Seagraves have been the workhorse Fire Engines of our fleet.
Btw. Mechanic miscommunicated the starter issue. The rear portion where the terminal post are located melted. He believed I may need a turbo blanket or some form of shield.
Pat
Pat,
This could have also been caused by the cable being loose or faulty connection. There is a history of burnt starter end bells from this happening. If it wasn't a bad cable connection or exhaust manifold leak of some kind then both a blanket and heat shield may be needed.
Mike
Is the rear end cap of the starter steel or aluminum? if steel, its not melted by exhaust. if its aluminum, it would have to get up to 1200 degrees to melt it. I dont think the exhaust gets that high even with a leak. I would look more at electrical, like the insulation rubbed off a wire and shorted on the end cap.
If the cables have worked themselves loose, possibly from the heat from the manifold, the resistance will go up and then when the starter is operated, the connection will generate still more heat. Hot copper passes less amps. As the temperatures cool in the fall and winter, the starter has to do more work to spin the engine and do it for a longer period. If the starter is not up to full speed, it will take longer to heat the combustion air making the starter even hotter for longer cranks.
I still remember how hot our battery terminal was when it melted trying to start with the temps in the teens and 8000 foot elevation. Vise Grips finally came to the rescue and it started.
Pierce
The idea of a faulty cable seems more likey - almost like welding, if it was arcing or lose connection and causing more resistance. I'll get more info - but THANK YOU for the input.
Pat