fromEdward Penrose reply-tosubaruvanagon@yahoogroups.com tosubaruvanagon@yahoogroups.com dateFri, Oct 30, 2009 at 3:14 AM subject[subaruvanagon] Vanagon Subaru starter problem, low power to start. mailing list Filter messages from this mailing list mailed-byreturns.groups.yahoo.com signed-byyahoogroups.com unsubscribeUnsubscribe from this mailing-list hide details Oct 30 (3 days ago) I have had a problem with one burned out starter, hi torque Hitatchi, and also sounds like I have a dead battery but alternator is putting out enough power. Someone kindly posted that there is a design issue with VW cable from battery to starter. Just found it is true and here is the bulletin, pse see fix below: Technical Information Group: 97 Number: 87-05 Date: July 31, 1987 Subject: Engine cranks too slowly or won't crank - battery cable Model(s): Water-cooled Vanagon, all Model Years A slow or non-cranking engine condition could be caused by high resistance between the starter motor and battery: * Check that the battery is fully charged. * Check the ground connections and battery terminals for tightness and corrosion. Clean and tighten as necessary. If the conditon still exists: * Install a new starter cable or larger diameter, Part Number 251 971 228G. * Install an extra ground strap from the transmission to the body ------------------------------------------------------------------------ I believe this is what burned out my starter and caused all the problems. I went to Interstate battery in Burlingame, CA and they made me knew cables (flexible and so much easier) double the size wire and about 20 mins to replace for $57! FYI tel 650-692-5949 - Mark helped me, great guy. 1. Change the ground strap from transaxle to body. $11.95. They'll male one. Part #: 7003-001. My invoice number was #: 73494. It is 4 X thicker and sealed. 2. Battery to starter cable. I removed battery. Remove cable, unbolt at starter. There are a series of plastic clips that you have to just remove by pulling out attaching cable to the body. Save and easy. 3. At the starter end the clip is a round hole. Tie a piece of cord and knot. Cord should be about 4 - 5 feet. 4. Pull the cable out through the batter compartment and it will pull through the rubber grommet and stop once the cord comes through. You use the cord to tie to the new cable starter end and pull back through the other way so you don't have to remove the fuel tank, really easy. 5. Pull the new flexible cord through and you re-install at starter end, tighten and put the battery back in, and bolt, you are done for 25 yrs more! 6. You'll have to change the accessory power to larger ends to go through the bolt on the larger battery clamp, better connectivity anyhow. 3 minute fix. Here are the parts of it helps anyone: 1. 9 feet #: 202104-100 2. 1 200505-0100 3. 2 5953-050E 4. 1 5954-050E 5. 2 5662-051R 6 . 2 5662-051B 7. 1 4002-050P 8. 1 160406-2006 My invoice #: 73493 Again at Burlingame, CA Interstate Battery. He knows the vehicle, what it was replacing and it all works perfectly. I hope this helps someone and sorry for the long thread. Edward