Originally Posted by Roadster (Post 263767)

Wow, and sometimes I think I have complications.......
Glad everything worked out....
Now the big question.....does the engine start???
Lol, couldn't help myself......:D

Originally Posted by secondchance (Post 263749)

Once again, the plenum comes off, plug wires disconnected, ignition coils and the coil tray removed and pulled the starter. So far, I have about one hour into this. 3 bolts removed from the solenoid plunger cover, cover popped off revealing the plunger and contact plates Got everything back together, intake plenum lined up, plenum bolts in. Looking for my torque wrench, I see two starter solenoid plungers - one old and one new. Noooooo!

I removed the plunger to take a pic showing two newcontact plates and must have forgotten to reinstall the plunger before closing it up… S**t!!!

So, I go through top end disassembly all over again, pull the starter, remove solenoid cover, install the plunger, the cover, back in the valley followed by coil base. 10 mm head bolt (M6?) to fasten ignition coil base, passenger side back, I had the bolt double side taped to a socket with u-joint to start threading. As I am bring the contraption to line up, the bolt drops right above the intake runners. I had all runners plugged with paper towels when I did this the first time. Second time around, with all the frustration of having to do the same again, I over looked closing off the injector housing openings. Now I am not sure whether the bolt went into the intake or dropped in the engine V.

Out of frustration I call Jagdpanzer to consult. ‘Course, calm and collected Phil tells me to get a pencil magnet and fish all the IH intakes.

I drive out to Advance Auto Parts, buy a couple of magnets on bendable goosenecks. As I am going through each intakes I get to cylinder #3, secondaryintake, I hear that “click” as the magnet gets hold of the missing bolt! Whew!!! Another hour and a half and finally everything is buttoned up. Sure was a day of hell! Hopefully, solenoid rebuild has fixed periodic non-start issue.

Originally Posted by Paul Workman (Post 263790)

So, now I'll ask: You didn't happen to see if the length of the plungers were the same, didja?

Originally Posted by secondchance (Post 263796)

Yes I did. It was after checking the length, I forgot to reinstall in the starter.

Originally Posted by Dynomite (Post 263793)

Been there and done that.......happens to all of us who decide to DO IT OUTSELVES :handshak::thumbsup::thumbsup:

Originally Posted by secondchance (Post 263796)

Yes I did. It was after checking the length, I forgot to reinstall in the starter.

Originally Posted by BlackZR1 (Post 263807)

secondchance, do you have a source/part # for the plunger? I've looked far and wide for the correct length plunger but had to settle for cleaning up the old one like Paul did.

Thanks,
Roger

Originally Posted by secondchance (Post 263819)

http://www.nationsautoelectric.com/densoparts.html

Call Nations Auto Electric. They actually have a real tech on the other side who will go through the book, figure out LT5 specific starter and identify plunger and contacts.

Originally Posted by Paul Workman (Post 266253)

As I rest my left foot on one of the original heads from my ZR-1, all I gotta say is...IT COULDA BEEN WORSE! LOL!