Frazzled last few inches of starter solenoid wire

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Old 12-22-2004, 08:46 PM
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Default Frazzled last few inches of starter solenoid wire

The wire that runs from the car's anti-theft relay contact to the starter solenoid is cooked to a frazzle for the last few inches where it connects to the starter solenoid. It has no insulation in that region. It seems to be sheathed for most of its run in the engine bay by a 3/8" dia (presumably heat shielding) insulated sheath. Q: Have you been able to replace this entire wire run, by pulling new wire through the sheath -- or just a portion? I guess that I'll use (10 AWG, I suppose) marine wire (Tinned strands give it a 200 deg C rating) or look in aviation supply shops for high temperature wire. Any BTDT?

Car: 1988 5000CSTQ, 150,000 miles
Old 12-23-2004, 04:41 AM
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Is there enough slack/give to be able to put a new end on it?
Old 12-23-2004, 05:50 AM
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Default Spliced mine with 10GA automotive primary wire....

cut off my bad end just like yours and crimped the new wire onto a decent section of the existing wire.
Has held up fine for a year now.
Old 12-23-2004, 09:40 PM
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Default Yep...

I've had to repair Alt wiring on almost all of my cars.

Simply splicing in new wire has worked well.

Steve
Michigan
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