Ken,

Sounds like that ground wire at the battery has gone bad. The higher than
normal resistance of that cable is limiting the current that can get
through the starter circuit and causing the cable to heat up.

Tim

At 02:46 PM 8/8/2006 -0400, Kenneth Wilford wrote:
>I am having a strange electrical problem with an 84 Vanagon GL with manual
>transmission.  The van came in with a "not starting when hot" problem and
>also a slow spinning over starter.  I found a problem with the temp II
>sensor wiring and fixed that easily.  However the slow spinning starter has
>me stumped at the moment.  I thought the problem was just that the old
>starter was hurt because the woman kept spinning the thing over when it
>wouldn't start.  I tried putting in new ground straps on the engine and also
>a new one on the transmission but this didn't help at all.  Next I tried
>replacing the starter with a new one and this did not fix the problem.  The
>strange thing that I have noticed is that as I am trying to crank the van
>over the ground wire on the battery gets extremely hot.  At one point it was
>smoking hot.
>
>Anyone have a clue on this one?  It seems like something is shorting out,
>but I can't figure out what that would be.  I would appreciate any advice
>you have on this one as it is causing me much head stratching.
>
>Thanks,
>Ken Wilford
>John 3:16
>http://www.vanagain.com
>http://www.strictlyvwauctions.com
>http://www.eurovan.org
>http://www.vwcabrio.org
>Phone: (856)-327-4936
>Fax: (856)-327-2242