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Wed Oct 07, 2020 9:11 am

One of the items I have been needing to address on my '87 hs been a sticky starter solenoid. It's the original starter, so it's time to replace it. So I ordered a TDI starter and adpater. The starter in the Bosch box has a sticker on it indicating the same sro408x Bosch part number but the casting is Valeo.

My understanding is that there is some clearancing necesssary on the mounting flange to clear one of the adapter mountig nuts, but even with the hardware removed, it's clear the adapter and the Valeo starter are not compatable, with the business end of the starter being off-center from the adapter center which prevents the two to mate properly. I'll probabaly end up at the FLAPS to see if they have a reman Bosch to compare, but has anyone else run into this?

Wed Oct 07, 2020 9:21 am

There are fitment notes on the westyventures site about Valero starters not working. Get a real bosch unit.

Wed Oct 07, 2020 10:01 am

I purchased a TDI starter adapter for a diesel bellhousing with a TDI single mass flywheel.

It did not work with the Valeo starter. Somewhere I have pictures, but the tooth count was different than the diesel starter and the proportions were also different. It would crank, but made a god awful sound.

As usual I had just the day to deal with it and ordered a vanagon diesel reman bosch starter. What showed up is one of the original diesel vanagon starters. The really large one. I was disappointed the TDI adapter did not work out in my configuration. I returned the starter adapter and got a full refund.

To be clear, this was an adapter for a vanagon diesel bellhousing with a TDI engine installed with a SMF TDI flywheel and clutch. Not a WBX adapter. I've installed Karl's on both WBX and aircooled bellhousings with no issue.

I was drawn to the Valeo starter because is was new not reman. I also wish I had the time to figure it out. Hope that helps?

Edit: found the pictures. No indication it wouldn't work.

Wed Oct 07, 2020 10:10 am

I'll hang on to the Valeo starter until I confirm the Bosch unit will work. I'll post a comparison if I can. I guess on the SMF for the TDI, the slight difference bewteen the two doesn't make a big difference since that's the application Bosch is mixing and matching them for not the 2.1 Vanagon.

Wed Oct 07, 2020 10:13 am

crazyvwvanman wrote: IIRC the originator of the starter adapter has warned not to use the Valeo version starter because it is different.

Here look at the yellow highlighted text in this link.

http://www.westyventures.com/parts.html

Mark

Wed Oct 07, 2020 10:18 am

crazyvwvanman wrote: crazyvwvanman wrote: IIRC the originator of the starter adapter has warned not to use the Valeo version starter because it is different.

Here look at the yellow highlighted text in this link.

http://www.westyventures.com/parts.html

Mark

That confirms it. As it happened, I purchased the starter and adapter from a different source, not knowing about the originator of the adapter. Thanks.

Wed Oct 07, 2020 12:27 pm

MarkWard wrote: I was drawn to the Valeo starter because is was new not reman.
Get a Bosch starter with a N suffix and it is new.

Wed Oct 07, 2020 12:40 pm

syncrodoka wrote: MarkWard wrote: I was drawn to the Valeo starter because is was new not reman.
Get a Bosch starter with a N suffix and it is new.

Next time. Thanks for the tip. It should have worked. Just did not have time to reinvent the wheel and was headed out on a road trip. Starter was getting a little lazy.

Wed Oct 07, 2020 10:42 pm

No opinion on the Valeo starter, but I just installed a Westyventures adapter & a new Bosch "short" 1.8T starter on my syncro. Works great.

https://www.thesamba.com/vw/forum/viewtopic.php?p=9470634&highlight=#9470634

Wed Oct 07, 2020 11:01 pm

The Valeo has an 11-tooth gear, which is very odd. The Bosch starters (SR0408X, SR0425N) are 10-tooth. With the larger diameter gear of the Valeo, they have an offset casting to compensate. The easy way to always tell Valeo from Bosch is the Valeo has external tie bolts, all Bosch starters are internal.
Another further note: I've also found out recently that some aftermarket / Asian starters have smaller bolt holes (and not precisely drilled either!) than Bosch, and cause fitment issues. I bought a new SR04025N Bosch and a cheap eBay version of the same starter to test - the Bosch fit perfectly and [13mm] bolt holes were spot on, the eBay starter [12.4mm holes] was a tight fit due to misalignment, requiring the holes to be reamed to 13mm. The adaptors were designed to precisely match Bosch 10-tooth starters.

Sun Oct 11, 2020 4:25 pm

So I sourced a Bosch starter and instead of grinding the casting so the upper bolt clears, I ground a flat onto the round bolt head. Fits well and if I ever have to replace the starter on the road, it's a simple swap. Haven't started it yet because I'm still fussing with wiring and the end-play on my distributor after I replaced the Hall effect sensor which is another story. Thanks Karl.

Sun Oct 11, 2020 7:23 pm

Igeo wrote: So I sourced a Bosch starter and instead of grinding the casting so the upper bolt clears, I ground a flat onto the round bolt head. Fits well and if I ever have to replace the starter on the road, it's a simple swap. Haven't started it yet because I'm still fussing with wiring and the end-play on my distributor after I replaced the Hall effect sensor which is another story. Thanks Karl.

What is the part number on that Bosch starter you sourced? (for the next guy)

Cheers

Sun Oct 11, 2020 7:52 pm

Bosch reman SR0408X. 1996-2003 TDI.

Sun Oct 11, 2020 9:05 pm

The SR0425N (new) starter is what I often recommend for those 'normal' applications, the SR0408X is necessary for larger engines and diesels, but can be used on all. The 0425 is the 1.8T starter and fits Syncros w/ locker much easier. And brand new means it theoretically will be more reliable long-term.

Sun Oct 18, 2020 9:52 am

As a follow up, the TDI starter works really well. I scrounged the proper solenoid connector off a big Audi at the local wrecking yard and spliced it in. The TDI starter spins my cold WBX over at at least 50% faster than the 33 year old original did that's for sure. Sounds much better too.