What are the odds...?

[wpoll]

So after "rebuilding" the starter motor in my 30d, I enjoyed three days of trouble-free motoring and the car was running beaut!

Until i suddenly got the dreaded "no crank, no start".

No click, no dimming lights, nothing at all when turning the key to start - just dead.

Carp, I think - what did I screw up?

Except, I was so meticulous with the process on the starter, I just couldn't imagine anything could be wrong with the starter.

So after a couple of days of stormy spring weather that kept me from diagnosing the issue, I finally got under the hood and did some testing. I pretty quickly proved the EWS was OK, which really left the starter solenoid or the ignition. A quick jumper lead test on the solenoid coil contact turned the engine over effortlessly, so that just left the ignition switch. Jumpering the contacts on the ignition switch was the final proof, with the engine starting easily. After removing the switch assembly and cleaning the starter (position 3) contacts, all is well again. I have new switch on order and will replace it, even though it's now working, since I really don't want to pull the dash apart twice in one week....

So what are the odds of getting a sudden and total ignition switch failure within days of working on the starter motor? And no, I never messed with the starter circuit when working on the starter, as all testing was done on the bench.

I guess the high current being drawn by the starter for a long time might have contributed to the demise of the ignition switch, since the solenoid pull-in coil is connected to ground via the main winding in the initial turn-over phase.

I guess it never rains but....