Nippondenso Starter Parts/ Repair
Denso Plungers
66-82603
66-82608
66-82607
66-82600
Solenoid Contacts
66-82750
66-82758
66-82759
66-82761
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Instructions for repair of Nippondenso
Starters
  1. Tools needed: 7mm or 8mm socket depending on model, 12mm socket and 14mm deep
    socket ( helps to use grinder on 14mm socket to thin edge out )
  2. Disconnect battery on vehicle and remove starter. Secure starter on vise.
  3. Remove cover from solenoid and remove plunger assembly.
  4. Use 12mm socket to remove nut from starter motor lead to solenoid.
  5. Use 14mm socket to remove nuts from battery and motor sides of solenoid then remove
    contacts, insulators and post from solenoid. Then clean dirt from inside of solenoid.
  6. Solenoid contact post on the motor side is attached to the starter contact. Secure
    contact in vise and gently tap post to remove from contact.
  7. Install new contacts into solenoid in reverse of removal. Take care to make sure that
    new solenoid contacts are level when you tighten the 14mm nut. If they aren't it will
    reduce the life of new contacts.
  8. Inspect solenoid plunger for wear. We recommend replacing solenoid plunger for
    maximum life but, if you reuse the old plunger make sure the surface is clean. Then
    reinstall plunger.
  9. Reinstall solenoid cap and bench test.
  10. Install on vehicle and you're READY TO ROLL!
Worn out Contact
View of contacts inside solenoid. Battery
side terminal wears faster because of
amps pulled through contact.
DIESEL STARTER REPAIR KITS
INCLUDE LARGER SOLENOID
CONTACTS FOR "MAX LIFE"
DIESEL REPAIR KIT
FACTORY CONTACTS
HEAVY DUTY CONTACTS
Starter Solenoid after repair and
"READY FOR ACTION"
View of "pitted" plunger contact.
Nippondenso starters are
used on a variety of
vehicles and equipment.
They are the largest
manufacturer of starters
and alternators in the
world. When these
starters fail it is almost
always a problem with
worn out solenoid
contacts. The common
symptom is a click- click-
click and then it will start.
Replacement units are
usually higher priced
than most because of the
superior design. Repair is
easy with the right  parts
and very profitable
because of the cost of a
new or rebuilt unit. Call
Adam if you have any
questions about repair or
application.
DENSO STARTER
Nippondenso Starter Parts & Repair Kits
QUALITY ELECTRICAL PARTS
SERVICE & DISTRIBUTION
SINCE 1930
1-888-334-2632
Denso Parts