This IS a common problem.  After 15-some-odd years, the slider in the
solenoid slides less and less easily.  Ours does the same thing and this has
actually been discussed at some length in the archives.  90% of the time
ours starts just fine, but sometimes, if it's hot, or if it's raining or
even if the planets don't align properly, it will not start.  A simple whack
on the solenoid is all it takes to free the worn out mechanism and start the
van every time.  The solenoid is just plain and simple WORN OUT.  I would be
too, after 15 years of that type of service.  I seem to remember some
discussion in the archives about trying to re-lube the mechanical workings
of the solenoid, but there's only one sure-fire cure for this, that I'm
aware of...replacing the starter.  I'm planning on replacing ours as soon as
this becomes frequent enough to become a nuisance or the hammer trick stops
working...whichever comes first. Good luck!!!

Rod Woten
'87 Westy
Des Moines, Iowa

-----Original Message-----
From: Shawn Luft [mailto:Shawn.Luft@COMPLETIONS.BOMBARDIER.COM]
Sent: Monday, August 11, 2003 9:36 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Starter doesn't work on long trips

Hmm, you see I doubt it's a lack of current because the starter works 99.9%
of the time.. however when I drive for 3-4 hours or more then it doesn't
re-start.  Also because it functions perfectly time and time again during
'normal' usage it makes me think it doesn't need replacing.

I was thinking that a component was somehow getting affected by high heat,
and when I wack the starter with a brick it was somehow freeing up the
funny problems.  D'oh.  If it was manual I could let it go, but it's
automatic and no starter means no start!

Thanks for the suggestions.  I'm still hopnig to find those ghosts however.
Uhm is it possible there are brushes on the way out or something similar?
I suppose I need to pull it off anyways and take a look but I thought it
may be a common problem that people know how to remedy.

- Shawn.