AJP 4,5 Starter Motor trouble

[Seppele]

Hello again, it Seems that my starter did not accept the long break. At the first or Second press there Are gear noises like the startet gear does not catch the flywheel gear. At the second//third try it worked. I lost the thread regarding overhaul kits for the starter motor. It's the one with 90something mm diameter. Thank you for your Support!!!
Seppele

[Gazzab]

http://www.ccw-tools.com/Automotive/Reduction-Gear...

Google is your friend.

[blecheimer]

And if you understand german (or use google translater) you will find a short tutorial how to repair the starter here:
http://tvr-forum.de/viewtopic.php?f=15&t=8245

Unfortunately I am a little busy and do not have the time to translate my tutorial. If anybody wants to try a translation I will gladly provide my pictures.

[Juddder]

blecheimer said:

If anybody wants to try a translation I will gladly provide my pictures.

As I'm planning on doing this to my 4.2, here you go

1. Problem:

When turning over the starter motor the only sound was a screeching noise. This was diagnosed as coming from the gearbox of the starting motor due to a bush being worn out which then causes the cog to move incorrectly.

2. Solution:

Conveniently, you can replace the entire gearbox unit in England for £59.95 / about 110 euros.

Tilton Starter Motor Gearbox

For an extra £42.43 / about 70 euros you can replace the solenoid too which as the Starter is already out it makes sense to do the two.

Tilton Starter Motor Solenoid

So basically you have a completely overhauled starter for about £100 / 180 euros which sounds like a good deal

3. Instructions:

First Disconnect battery!

Then make room:
- Remove Scuttle panel (1)
- Remove Passenger side air box (2)
- Remove the last three Intake Hoses (3, 4, 5)



- Unclip the Passenger side throttle linkage (6) (it's only a small pin so don't drop it!)



NB: I've read that 4.2 AJP owners must probably also take off the Fuel rail

Now remove from the top to the two Allen screws of the starter. The are pretty tight but come lose after a sharp tug.

Be careful that nothing falls into the engine or the big hole just above the clutch.

The rest is simple:
- Disconnect the plug to the solenoid that is dangling just above the starter.
- With a little effort you can turn the starter now, so that the back with the cables connected is now facing forwards. I found it easier to disconnect the two thick cables before removing the starter.

The starter is now free and can be taken out - note: the space is pretty tight but the starter does actually come out.



4. Refurbing Starter Motor:

- Remove the front panel from the stater (three screws).
- The gearbox is held in place with four screws which are difficult to remove
- Remove the old grease and cover the entire well generously with fresh grease. I have used high-temperature grease, because the starter sits in a hot area.
- Anyone who wants can also exchange the solenoid. This is achieved by removing two large bolts at the back of the starter, only the two large long bolts, not all four. Then you can pull the front part (not the rear end!) and the solenoid without too much hassle replaced. NB: You have to re-use the old spring for the solenoid as the new one does not fit properly.

[blecheimer]

Like!

[Seppele]

Hi all, many thanks for the lost links and the manual which is very useful and would perfectly fit into the "how to..." area.
@Blecheimer...ich bin ein bayrischer Berliner

[Boatbuoy]

Judder / Blecheimer

If one of you fancies copy and pasting the translated guide into a new thread with an appropriate title I'd like to add it into the 'how to' guides sticky.

Olly

[blecheimer]

Just Copy/Paste?
That is easy, I can do that.
http://www.pistonheads.com/gassing/topic.asp?h=0&a...