Matt,
Sure the repair can be done, but if the starter is old enough for the
wire to disappear, it most likely is ready for replacement anyway. It
will have to be disassembled to replace that wore and the connection to
the coils is not a simple crimp or soft soldered. The wire is a braided,
6 gauge.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Matt Sutton
Sent: Thursday, June 22, 2006 3:00 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Solenoid-to-starter wire replacement?

Hi Folks,

    On a trip to Philadelphia the other day, the van refused to start or
even turn over after a rest area stop. Tried jumping it, even though
there
were 12.5 volts at the battery, and got nothing. Eventually we got it
running with a push start, with help from some repo guys who were towing
the
truck next to us.  The next day I found the short wire from the lower
solenoid terminal to the starter to be corroded beyond repair; it just
crumbled as I tried to clean it.
    It seems like the solenoid is still functional (it clicks when I try
to
start), so maybe I really just need to replace that wire that terminates
inside the starter motor. Looking at the Bentley, it seems like the wire
feeds the field coils of the motor. Can this repair be done? Has anyone
done
it? Any educated guesses about what gauge wire to use, things to
check/worry
about while the starter's apart, etc. would be much welcomed.

Van info: 88 Gl, manual trans, approximately 220k on the original
engine,
though by the look of it the starter may be a rebuild.

Thanks,

Matt Sutton
Brooklyn NY