David, as I have said on the list before.  There is a stock Bosch solution
to the sticky solenoid problem.  It is known as the Bosch WR-1 relay.  Put
"Bosch WR-1 " as the search string in google and hyperlinks to instructions
and vendors follow.  I have mine mounted under the rear seat.

John Lauterbach
Macon, GA
'84 7-passenger

----- Original Message -----
From: "David Marshall" <vanagon@VOLKSWAGEN.ORG>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, January 25, 2004 2:00 AM
Subject: Re: Can I buy just a solenoid?

> Before you go ripping apart your starter, measure the voltage to the
trigger
> wire when you try to actuate the starter.  Chances are very good that
there
> is some corrosion in this wire and a huge voltage drop as it does take
some
> current to make the solenoid go.  I have seen cases where people spend
mega
> dollars (me included) on a nice Bosch reman starter only to have the
problem
> come back a few weeks later as the problem was never really the starter.
My
> solution was to install a 30A relay back there to trigger the actuator.
Use
> the original R/BK wire to trigger the relay and use the main 12V lead to
the
> alternator to feed the relay.  Most relays will trigger with as little at
> 5V, however you won't see this much of a voltage drop as there is almost
no
> current needed to trigger a relay.  Try the $5 relay before you get the
> wallet and tool kit out to fix the problem.
>
> Good luck!
>
> David Marshall
>
> Fast Forward Automotive Inc.
> 4356 Quesnel-Hixon Road
> Quesnel BC Canada  V2J 6Z3
>
> http://www.fastforward.ca    mailto:sales@fastforward.ca
> Phone: (250) 992 7775        FAX: (250) 992 1160
>
> - Vanagon Accessories and Engine Conversions
> - Vanagon, Transporter and Iltis Sales and Importation
> - European Lighting for most Volkswagen models
>
>
> Due to the large volume of email  we  receive,  PLEASE  include  previous
> emails when responding.  This will allow us to read the complete dialogue
> in one message and will result in quicker and more  accurate  responses.
>
>
> -----Original Message-----
> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
> Of Anonymous Digest
> Sent: January 24, 2004 5:58 PM
> To: vanagon@GERRY.VANAGON.COM
> Subject: Can I buy just a solenoid?
>
>
> I have a friend with starting problems, and it sounds like it might be the
> solenoid. Haven't actually climbed under and done any testing yet, as like
> for many of us, I am afraid of freezing my butt to the garage floor, but I
> would like to know the options for him when the time comes.
>
> I don't see any solenoids on the vendor web pages, just titanic prices on
> starters! Yikes :-)
>
> What do we do when the solenoid is bad? Rebuild. Find a junk yard? Buy a
> big hammer?
>
> On a related, but somewhat different topic:
>
> I tried searching the archives for past threads on starter problems, but
> you know what? There are so many repetitions of the same paragraphs from
> not snipping the replies, that the flow of the threads is not there, and
> its really quite difficult to find your way through the real info, as you
> find yourself reading the same paragraphs/text dozen times.
>
> I know asking for editing the replies is just usually just ignored, or
> excused. I makes me crazy because I read the digest mode,  but the real
> reason we ought to snip the replies lies in the archvies. They are huge,
> and a treasure filled with priceless information, but its getting harder
> and harder to use it because of the redundant text.
>
> Just my opinion. Hope no one minds me saying it 'out loud'
>
> Thanks for any solenoid advice.
>
> John