Every once in a while my starter won't work, as if the clutch isn't engaged. No clicks or anything. It works fine after a few solid taps with a hammer.

What's going on inside the starter that causes this, and what needs to be done? Haven't had this problem with any other vehicle, so I don't know if it needs to be rebuilt, replaced, or something else.

I've heard about old VW bugs doing this and how some guys would drive like that for years, occasionally giving their starter an 'attitude adjustment'.
It's been many years since then, and I don't remember anything else about the problem. Luckily, I did recall the hammer trick and wasn't stuck in a parking lot.

 

Its most likely the brushes or the solenoid plunger/contacts ( maybe both ) I rebuilt mine for around 42 bucks. I called a starter shop and got the parts there, not from a parts store. ( napa does not even list the parts ). The guy I bought the 92 from had been bangin it for a while. The starter is full of dents.

 

i had the same problem, i just put stuff listed above in it and it worked for a while. then it started acting up again. sometimes the contacts will "weld" themselvs together and prevent it from working. in your case they might just need a good cleaning with some sand paper. or just save some headache and replace it all lol

 

These starters are ridiculously easy to recondition.

I would much rather rebuild the starter, than do the work of removing and re-installing it.

There is an excellent pictorial write-up by BC847 located in our sticky.

In that write-up are links to various suppliers of the improved over-sized contacts, plus brushes and plungers.

E-Bay has dozens upon dozens of sources for the rebuild kits that come with every piece you will need.

If the starter is bad enough to need a whack, most likely two of the brushes are worn so thin that they no longer contact the commutator; they could even be completely worn away and the contact is being made by the wires instead.

If that be the case, it ain't gonna be long before whacking isn't gonna do any good.

ARTICLE :

https://www.dieseltruckresource.com/....html?t=141395

ENJOY

 

Now that you have new brushes, contacts, and plunger in the starter, remove and CLEAN the big battery GROUND at the front of the block.

Wire-wheel-brush all the starter mounting-bolts, chase both internal and external threads, and coat with anti-sieze.

CLEAN both cables/posts at the battery.

Test and replace the battery if questionable.

A weak battery, or loss of current caused by poor connections, will spell death for a starter.

Contacts and brushes suffer from excessive arcing caused by poor conductivity and lack of power.

The condition most battery-cable connections I see are in, it is a miracle a lot of vehicles will start at all.

 

I think there is a kit for the solenoid on Genosgarage.com. It was rediculously easy, and it was like $30-$35. It is also an "upgrade" kit and the contacts are MUCH bigger. Idk if it will help the performance of the starter, but the contacts will definitely last longer that way.