Fechino Files: When Something Easy Should Only Take an Hour

Words: Steven Fechino

My days all tend to start the same: wake up happy, work out... still happy. Make a phone call to check in with a buddy of mine, then I start my actual work for the day. So last weekend, I did what every masonry contractor has to do from time to time—I had to replace a truck part. No big deal, right? That's what I thought too. Since I do masonry projects for folks as favors and do not own a masonry construction company that creates income, I was elected (by me) to be my own mechanic.

Remember I said I begin happy? Well, I was replacing a starter solenoid on an older small dump truck, so this will be a primer on how to replace a starter, with sidebar notes so you do not make the mistakes I did. I grabbed a few wrenches, my phone, a rag, a headlamp, and an old yoga mat my daughter gave me so I didn't have to lay on the ground. I was figuring about ten minutes to take it off and then off to the auto parts store to pick up a replacement.

The first thing I did was unhook the positive battery cable. Then I took photos of the solenoid wiring—I must have taken 15 more photos than I needed to—but still probably missed something along the way. Then I got started: unhooked the positive cable from the center post, unhooked the little post that connects the ignition (the small S terminal), and then I unhooked the return wire from the ignition (the small R terminal). At this point, I decided to unbolt the mounting bolts from the engine block.

No problem—unbolted the first bolt and when I went to unbolt the second bolt, well, I could not find it. I fished around with my hand and finally found it. I had to lay under the transfer case and reach my hand over the frame and down to the starter, wwweeelllll... my wrench was too long. So, I crawled out from under the truck, went to the shop, and got a shorter wrench. By now I am 20 minutes in and thought it would be quick now. Silly me—by the time I got back into position, the short wrench could only turn about a 1/16 turn. That bolt took about 20 minutes to finally get it out. Still under an hour, hands covered in black grease, I had almost an hour invested.

Here is where the importance of this article can save you money from my mistake. When you purchase a starter, bench test it before you install it. Well, I did not. Yup, I installed it and spent almost an hour putting it back in. When I jumped in the truck to turn it over (yes, I hooked up the positive battery cable), I got nothing, not even a click. Troubleshooting a starter that is installed is easy: take a test light, ground it, and touch it to the positive cable on the solenoid to see if it lights up—it did. Then I took a wire and connected it to the ignition side of the solenoid, ran it to the cab, connected it to the test light, grounded it, turned the key, and the light came on but still did not click.

So, I took the starter off; I think I broke my time record and did it in 38 minutes. I took it into my shop and "bench tested" it. I should have done this before I started the initial installation. To bench test, you hook the jumper cable to the center of the solenoid and the negative to the starter frame. When you connect the positive cable, the solenoid will push the pinion gear out as it spins the starter. That is a working starter. So I took mine back because it failed the bench test. Got a second starter and bench tested it—it worked.

Crawled under the truck, hooked it up, crawled out, turned the key, and nothing. This starter had the solenoid turned 180 degrees, and I could not see it when I hooked it up. Who does this? I reversed the wires and boom, she kicked. Check the new parts that you purchase; if you cannot, it is likely the expensive ones can be checked at the auto parts store. Check for wiring connections, wiring orientation, and physical size of the part. These simple steps could save you time and frustration. I also recommend for each piece of equipment that you write the engraved part numbers down, what wrenches you used to install the part, and any other little things that will save you time the next time that part goes out. This is important for oil and air filters, wipers, types of oil and antifreeze, and even smaller parts that you may need to remember. But you will not need to if you write it down.

I make mistakes and share my endeavors with you so you can be more productive with your business.

As summer has arrived, so has the heat. Stay hydrated and pay attention to your crews; you do not want anyone laying out because of the heat, that only makes more work for you. Oh, and yes, you care about your crew—almost forgot that.

Lay one over two, be safe.

Fechino Files: When Something Easy Should Only Take an Hour

About: Fechino Files

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