Starter Motor Replacement- Struggling.
 

Due to the starter needing a sharp whack to wake it up far too often I began replacing it today. Got a used original from a Volvo breakers with a year guarantee.
Removed the old one, which is a Bosch.
I’ve got as far as seating the replacement ready to bolt up.
Got the trigger wire (green) re-connected.
But the two big red wires with the washer type ‘ends’ that go onto the solonoid are where I’ve stumbled. Now only one will reach, the other is about 2 inches ‘short’. Obviously it’s caught up on something but can’t for the life of me work it out.
Just wondered if anyone else has had this issue doing theirs and could point me in the right direction. I given up for today, and will go back after sleeping on it!
Thanks in advance.
EDIT: Might help if I tell you which car, it’s the 99’ T5 SE auto.

Wasn’t expecting any replies. Just sounding off really. Sure I’ll crack it. Thanks for looking anyways.
Hey if I ever put this one up in sales, ignore it’s a turd .
Never had a Volvo like it. Lol.

Seeing as you haven't bolted it up yet I'd be tempted to remove it again and compared both starter motors side by side. It may just be the positive lug is in a different location on the new solenoid as opposed to your original.

Baffler , you were spot on, it’s taken me all this time struggling and pulling my hair out. The two are slightly different, the old one has the solenoid on the side, so the wires reach.
The supplied one has it on top, so only one wire reaches. And yes it’s taken all this time to realise. DOH!
https://i.ibb.co/HPXQY9q/4-DD82809-F...97-CE57-A4.jpg

I sent an email to the Volvo Saab breakers I got the starter from with the pic in the above post just before posting.
Got a reply, the correct part is being sent out today. Great service.

You could open up the solenoid or main motor and find that there's very little required to restore its operation.
There are starter refurbishment videos on my YouTube channel.

Thanks Chesh, I’ll take a peek. The ‘old’ one which is a Bosch does the random no start thing. As in nothing when you turn the key. A quick love tap with a bar and off it goes again, lol.

The solenoid internals may just need a clean or you could just swap over the entire solenoid from the replacement unit if it's compatible.
3 x Torx screws and one nut removal is normally all that's required.

Are they letting you keep the other? If so it looks like you have a spare for your '04 :tounge_smile:

Yes , no mention of having to return it. It was £30 quid or so delivered, I’m sure they can swallow that.
If it fits the phase 2 then that’s fab. :party: