need starter removal help

[Tugela]

Need some detailed advice here: I'm replacing my starter and can't remove the two allen mounting bolts.

Let's start with the lower bolt (the one closest to the driveway): I can't get enough torque on my short allen wrench to loosen the bolt. My longer allen wrench is too long to work in the space. Those of you who have done this successfully, what's the trick? Allen socket? Note: drive shaft is in place and is staying there because that hardware is also frozen tight. Long story.

Assuming I can get the lower bolt off the starter, how do you even access the upper bolt to loosen it? It's a crazy tight space and I can't even see up there. RAVE says use a 230mm extension on your ratchet to access from in front of the engine mount. This is a specialized tool I don't have and would prefer to not have to buy to complete this project.

Then again, the alternative is a truck that won't start, so I may not have much choice.

Removing hardware on this truck is always the most difficult part of the job.

 

[Tugela]

Update: so 230mm = 9.0551181102362204724409448818898 inches. I can piece together the extensions I have to make one this long, but damn, the access to the upper bolt is a beeyatch. Off to buy an 8mm allen socket.

 

[listerdiesel]

One of those sets of tools I've had for years to use on propshaft bolts on European trucks etc. The original set was 1/2" drive, but I got a 3/8" drive set a few years back.

That and a couple of LONG 3/8" drive extensions.

You never stop buying tools!

Peter

 

[Tugela]

Okay, I understand having more tools is good, but any suggestions on the original questions?

 

[rwhitmo04]

I used the allen socket and stacked extensions together until I had enough room to get some torque on the ratchet. A standard 3/8" drive ratchet wouldn't do the trick, so I had to stack the extensions until I could fit the breaker bar on there.

A ratcheting breaker bar probably would have been beneficial.

 

[pdxrovermech]

bottom: remove O2 sensor, 3/8, allen socket, extensions, cheater bar
top: allen socket and ratchet.

i hate that heat shield.

 

[fishEH]

Bend the heat shield out of your way.
Clean out the socket head cap screws REALLY well before trying to remove.
Use an allen socket and a bunch of extentions.
Replace the socket cap screws with standard hex cap screws, they're 3/8-16.
You can replace the top one with a really long bolt, like 8", and a spacer sleeve so you wouldn't need all those extentions next time.

 

[mulisha00]

Put the allen wrench in there and use a wrench on the allen key also has worked for me.

When out buying your tools buy some brake parts cleaner.

Use the little straw and clean all the grime from the heads of the allen bolts.

People always talk about extensions ect. I found it much easier to do it without an extension.




Go buy the correct bolts and replace the allen heads. Don't put them back in. I've had to cut the head off bolts before to remove the starter.

 

[Tugela]

Okay, job is done. The allen socket bit was the key. Got really lucky and seated the retaining bolt on the heat shield after only 4 minutes of fumbling. Glad that's done. Ultimately extensions were not necessary. Thanks for the suggestions.

 

[eliaschristeas]

did you soak those bastards in PB like I said? Next time just use an air chisel or a flamethrower.... once the body melts to the ground you will pretty much have all the access you need.

 

[Tugela]

E, there are days when taking a flamethrower to the Disco is tempting. But then I think "Hey, it could be worse. I could own a Freelander."

 

[aliastel]

For the future, I've found the easiest way is to put the axle on a jackstand, remove the wheel on that side and then gently bend the inner fender out of the way enough to just reach in there and undo the starter bolts. No extensions necessary this way and its very easy to see what you're doing. I've done it the other way with extensions from the front and it is a lot more difficult. Also, I always replace the bolts with new ones each time, and install them with some anti-seize. I believe PT replaces the bolts with studs if I remember correctly.

David