One last thing: Cam the bendix fully open, the force must be against the clip. Measure across the assembly to get the overall length. Measure the internal depth of the housing from face to face where the bendix fits. You may need some measuring tools and spacers to get it done (you might need to measure individual distances and add them up).
The point here is to confirm that there is enough space available that the bendix does NOT wedge inside the cases. This means it can cam all the way open and still have some end play. There may be some shims used to reduce wear on the aluminum cases, add them to the measurements.
If the bendix wedges, the drag will cause it to draw higher current. If everything measures OK, then you're back to replacing the starter motor.
__________________
2011 EC250E
|