Originally Posted by lowtechredneck
has anyone out there ever fixed a stipped post on solenoid? i read about a selftapping repair stud, but cant find where to get it. any suggestions?
"Traditional" GM starter solenoids are reparable, but you need to remove the starter and use another stud in place of the stripped one.
Shown below is the inside of the solenoid cover. The arrows point to the contacts that are also the large copper studs that protrude through the cover that you connect to the power cable and to the starter motor, as well as the other smaller silver colored stud used to connect the ignition resistor bypass wire and the wire from the ignition switch to, seen in between the copper colored contacts (one of those is missing).
If you have a non points-type ignition, only one of the smaller terminals is used (some solenoids are only equipped w/one small terminal for the ignition switch), so simply take the good "spare" terminal (if it's there) and use it to replace the stripped terminal. Reinstall the bad one in place of the one you use to keep dirt and water out of the solenoid. Or take a terminal from a spare solenoid.
The studs/terminals can be rotated 180 degrees to use the fresh, unused side of the contacts. This trick will effectively double the useful life of an ordinary solenoid, and if carefully resurfaced, the contacts/solenoid will last even longer. If you have stripped out the female threaded hole in the large copper terminal that connects to the motor (6 o'clock position), the hole will need to be retapped using a metric tap and screw to fit, possibly a self tapping screw or replace that stud entirely.