HowTo: Starter Motor Gearbox Replacment
Discussion
Big Thanks to Judder for the translation!
See original thread here
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.
See original thread here
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.
Edited by blecheimer on Friday 4th March 14:39
Edited by blecheimer on Friday 4th March 14:40
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