Engine/Transmission (1994 - 1998) Replacing Starter Contacts (Advice)??

[Bob Ellithorpe]

I'm in the process of replacing my starter contacts and plunger Assy. In the process of doing so,I deceided to take a break and try to address a few issues I've run into.

The first thing I noticed was that only one of the contacts were worn the other was in like new condition.

When trying to remove the nuts (17mm) that hold the contacts in I first tried to use a socket,this can lead to rounding off the flats of the nuts as there isn't really enough of the nut sticking up for a socket to get a good bite on. Instead I used a combination wrench and used the open end to get a better bite.

Something else that I haven't seen anyone comment on is that the two bolts that hold the contacts in are different lengths and the longer bolt has serrations under the head where it makes contact with the contact. If you're not real careful and don't line these up with the contact you can have a contact that's out of line. I used two pair of channel locks, making sure they were lined up squarely,then squeezing the bolt serrations into the contact. Also install the longer bolt and contact first.

Nowhere have I seen any mention of the small rubber seal on the longer bolt. I assume this is to keep water out!! It would be nice to see this included in Larry B's Kit !! Also Larry's instructions say to remove the spring from the plunger. nowhere does it say to replace the spring as a new one isn't included in his kit.

Some of you will say this stuff is ticky tac, but I like to think I'm detailed oriented Nuff said!! Time to get back to work!!

 

[LarryB]

Bob

Thanks for the heads-up. I have made some changes to my instructions. Check them out here and see if this helps.



Also some Frequently Asked Questions that may help



Larry

 

[Dennis Garrett]

It's a good time to take it apart, & check your brushes too. Sand the glaze off the comutator, & blow all the dust & dirt off with an air gun before you put it back together.

 

[Dieselnerd]

Good instructions Larry! I didn't have any real problems changing contacts (except my ball fell out but I found it), it's really a simple process that is almost easier than it looks.

 

[SlyBones]

So what kinda bolts is the starter held on with? Could not get them off. Socket/wrench would not hold. Looks like 12pt or something.

 

[illflem]

Sly they're 12pt 10mm and are on really tight. Use a higher quality socket or you'll round it off.

 

[Bob Ellithorpe]

Starter bolts

The bolts are on very tight !! I had to use a 1/2 ratchet with a cheater pipe on the bottom two bolts. On the top bolt I had to use a 3/8 ratchet with a 3"and a 6" combined extensions as my 1/2" extension was to long and I had interference with the 1/2" ratchet. I also had to use a cheater bar to break the top bolt loose. Make sure you get on the bolts squarely so you don't round them off. On the left hand bottom bolt, tuck the plastic breather pipe up out of your way to get a better shot at the bolt.

 

[shendren]

i used a box end wrench on all three.