Did you get a chance to inspect the old wire? I'm curious to know
whether the problem that caused the slow cranking was visible.
--
Rocky J Squirrel

Jonathan Poole wrote:
> Even after installing a new starter, new starting battery, inspecting and
> cleaning all connections and grounds my van still cranked slowly when hot,
> if it turned over at all. I put off replacing the battery to starter cable
> until last because my cable showed no corrosion or deterioration and because
> changing the cable seemed like it would be a difficult task. A few days ago,
> after my van wouldn't start in the heat I got motivated and changed the
> battery to starter cable which solved my slow cranking issues. Below is my
> account of the easy job that may be helpful to some of you contemplating the
> change.
>
> After my first stop on my day-trip my van wouldn't restart and I decided
> that part of the days recreation needed to go towards fixing my starting
> issue. In the next small town I stopped at a tractor dealership in hopes
> that they had the cable I needed and the ability to press on the ends etc. I
> had to leave my air-cooled Westy idling in the near triple digit heat (thank
> goodness for the extra oil-cooler/fan) while the guys inside gave me
> directions to a machine shop that could make a new starter cable for me. At
> the machine shop they were confident that they could make whatever cable I
> needed and also said it would be fine for me to do the work in their parking
> lot (that is unfortunately gravel, oh well). Not really knowing what I was
> getting into I shut off the van and dove into the cable removal/replacement.
> In the end the entire process only took around 30 minutes and cost $35. I
> got them to make the cable using wire that was one size larger than the
> original that I removed from the van. I believe that they used 1 gauge wire
> but I'm sure that folks on this list can make better recommendations on what
> to use. The replacement process that I used went as follows:
>
> Disconnect/remove starting battery from beneath the passenger seat.
>
> Disconnect the starting cable from the starter.
>
> Remove the cable from the van moving forward from the starter by removing
> zip-ties/and other wire retainers and pulling the starting cable clear of
> wires/frame etc. Pay attention to the routing so that the new cable can be
> run along the same path.
>
> When the cable is loose up to the hole/passage above the gas tank/next to
> the shift rod attach a pull-cord/string to the end that had been connected
> to the starter. I used duck tape around the string instead of knots for
> this.
>
> Pull the cable up into the batter compartment slowly and smoothly until the
> string comes into the battery compartment. Be sure not to pull the string
> all the way into the hole above the gas tank.
>
> Disconnect the string from the starter cable and have a new cable made using
> the old cable as a guide for length/etc.
>
> Connect your shiny new cable to the string, then pull it back through with
> your string until only enough cable is left in the battery compartment for
> connection to the battery.
>
> Re-route/install the cable along the old run back to the starter
> installing/reinstalling clips and zip ties as needed as you go. Be sure you
> follow the same path as the old cable, or that the cable is secure from
> hanging down/snagging/chafing etc.
>
> Reconnect the cable to the starter and inspect the wire run making sure that
> it is well routed and secured.
>
> Reinstall the starting battery.
>
> Test by starting your van,, if all went well then you are done!
>
>
>  I felt a bit silly for having put this off for so long once I had
> finished.  Throughout the rest of my trip, in high heat, my van cranked and
> started quickly every time. Maybe now that my starting system is in such
> good repair it is time to get a bigger engine for it??? ha ha.
>
> So, if you are considering this change I say go for it.  Had I known that
> these cables were so commonly problematic, and that replacing them was so
> easy/cheap, this would have been the first part that I replaced when trying
> to fix my slow cranking van.
>
>  Jonathan Poole
>
> '83 AC Westy