Replacing starter motor on AE92

[LeeRoy]

As I said above I bought a second hand one for $90. A rebuild would probably be around $100-$150 at a guess.

Mine had heaps of meat left inside it was just the contacts were really black and burnt which made it intermittently not work. It was also pretty dusty from the brushes wearing over the years. Since I opened it up and cleaned it out I havent had any issues with it not starting - not even 1. So it didn't even require a rebuild just an internal clean.

On a side note I did the front wheel bearings on the weekend which were shagged. Making a fair amount of noise, some play etc. My car has 225k kms so might be worth checking yours if you have similar milage.

[BoostBoy]

Okay so removing the starter was a lot easier than I thought...easy to get to the bolts and move it out...so i was happy with that.

I downloaded a 4AGE manual and ran through all the tests that can be performed on the starter to see if it's operating properly...it passed with flying colours. Also while I was at it I cleaned the contacts....I couldn't open up the main casing to get all the carbon dust out, but the tests showed that it worked so I probably didn't need to.

So now not sure what would be causing the problem :S

[LeeRoy]

Okay so removing the starter was a lot easier than I thought...easy to get to the bolts and move it out...so i was happy with that.

I downloaded a 4AGE manual and ran through all the tests that can be performed on the starter to see if it's operating properly...it passed with flying colours. Also while I was at it I cleaned the contacts....I couldn't open up the main casing to get all the carbon dust out, but the tests showed that it worked so I probably didn't need to.

So now not sure what would be causing the problem :S

It's probably filthy inside so i'd DEFINATELY be opening it up...especially since you went to the effort of removing it

What tests did you do?

[BoostBoy]

Yeah i have no problem with pulling it off again....I just can't loosen the screws that hold together the main housing...used WD40 and everything...still couldn't do it...they are Phillips head screws, any tips? Also do I need to use new O-Rings if I do manage to get inside it?

I did the performance testing with the battery, as specified in the manual which included seeing if the plunger comes in and out, and the starter rotating steadily.

[LeeRoy]

Don't destroy the head of the screws. My suggestion is to soak them in WD40 or penetrene for a while.

When you have a go at them, use some valve grinding paste in the head to help the screwdriver grip and also get some multigrips or vice grips around the head. so your not soley relying on the screwdriver. I did this the other day on some screws holding a backing plate on. Screwdriver alone was destroying the head but with the multigrips it was so easy. I got the old man to help me so i'd suggest getting someone to give you a hand.

So in summary...
- WD40 the bolt, then keep applying it every 5 mins for 20 mins or so.
- Valve paste in the head if you have some.
- Screwdriver and multi/vice grips held as tight as you can, turning both at the same time.

Hopefully that works.

My reasoning for opening it up is because mine worked fine out of the car as well - but this is usually due to the dust being loosened during removal. However, once you put it back in it will probably work for a week if your lucky before becomming an intermittent problem again. The problem will be both dust inside it, and the contact for the solenoid (the thing that throws the gear out) will be black from arking over time - same as the spark you get when you put a battery terminal back on - this is what happens in your starter every time you start and over time if covers the whole contact and it stops working.

[BoostBoy]

There's no way vice-grips can get in there or I would have done it already...the screws I'm talking about are the 2 phillips head screws where the starter pinion is...they are inside a shaft. If you know where I'm talking about, you'll understand how hard it is! haha

I guess I'll keep trying the WD40 until it gives way...I've already damaged the head a little bit...thanks for your help

What about the O-Rings?

[LeeRoy]

I didn't buy any new bits when I cleaned mine so yours should be ok. Sorry, thought you were talking about the ones that run down the side.

If you can't get them off just drill the heads off and replace them.

[BoostBoy]

Sooooo...I finally got the bolts off....I tried once again soaking in WD40 and using all my strength to turn the bolts and I couldn't do it. So I gave up and started drilling the heads out....but the drill bit just wasn't cutting through...so I almost chucked in the towel, but then I found a special tool called an Impact Driver that is specifically made for stubborn bolts!

So luckily with the tool I was able to get the bolts out....I didn't drill too much of the head away or I would have been stuck!

Now I'm stuck on another part though! On the housing where the armature is, I can't get the field frame off....this is the metal frame in the left part of the picture....it should come off just by undoing 2 of the little screws at the back...but it won't....it seems to be connected to the armature in some way.

What did you do to get this off? Do you have to take the brushes off somehow first?

[Aust162]

Hey mate, have you seen this thread?

http://www.toymods.net/forums/showthread.php?t=3282

Do you have a relay setup at all? this sounds like your problem to be honest. REALLY common. (edit: sorry if i missed something in the thread)

[-GT-]

Yeah my thought reading through the first page was that you'd seemed to miss one key point - you're all talking about heat from the turbo+manifold causing the problem, but he says he has the problem when first starting it, often on cold mornings. Sounds completely unrelated to the turbo setup, and he's tested the starter and it's fine.

Didn't read much of the thread linked above but it seems to be along the lines i was going to suggest; sticking starter relay or maybe just the contact of the starter signal is a bit iffy? Signal plug to the starter has got a little loose? I've had both happen and it sounds much more like what you're describing, rather than anything physically wrong with the starter itself.

Before you start pulling apart a starter that you said is working perfectly after testing it, i'd be looking at the bits between the key in the ignition barrel and the starter, especially as it's an intermittent fault.

[BoostBoy]

Yeah you're right I think...I pulled it apart again and I have the feeling I've just wasted my time. I checked every part and they were all good and then cleaned and re-greased everything...performed the same tests again and it works fine out of the car every time.

I put it back in the car and after a few starts, same thing...intermittently no starting. It definitely feels like something not working between the ignition key and the starter...next thing I'm going to try is the relay setup suggested by a few people and I'll see if that solves my problems.

[LeeRoy]

Apologies if I convinced you to pull it out. As I said mine was doing the same thing and all I had to do was clean it and it's worked fine ever since.

[Cuzzo]

How have you not tried the relay setup?

Did you have a search around on toymods? That would one of the first things i would have tried.

[BoostBoy]

Apologies if I convinced you to pull it out. As I said mine was doing the same thing and all I had to do was clean it and it's worked fine ever since.

Nah mate all good...I wanted to be thorough! Plus it's easy for me to take it off since I don't have an exhaust manifold in the way. I still couldn't get the armature out, but from what I could see it looked fine...gave it a few knocks and only a little bit of dust came out. Brushes where all making good contact, so it didn't worry me...

How have you not tried the relay setup?

Did you have a search around on toymods? That would one of the first things i would have tried.

Yeah I saw it a while ago, but since I had the car off the road anyway and the starter motor was easy to pull out, I thought I would try that option first to make sure.