Starter motor, 3rd gen. Can't remove it!!!

[solent_surfer]

Have traced a starting problem to the starter motor and reakon it's the contactors. Bought the kits, but can't det the thing out. As far as i can make out, there are 2 bolts holding the starter in. I loosened the bottom one but can't get at the top one. Am I doing this right? is there an easier way to get it out, if so PLEASE ADVISE. I hate not knowing if my surf will start the nxt time i wanna go somewhere!

if anyone's done this one already, please let me know. Mines a KZN185 3.0 '96 5 gear Manual

[phoebelala]

Have traced a starting problem to the starter motor and reakon it's the contactors. Bought the kits, but can't det the thing out. As far as i can make out, there are 2 bolts holding the starter in. I loosened the bottom one but can't get at the top one. Am I doing this right? is there an easier way to get it out, if so PLEASE ADVISE. I hate not knowing if my surf will start the nxt time i wanna go somewhere!

if anyone's done this one already, please let me know. Mines a KZN185 3.0 '96 5 gear Manual

I did a 2.4 some time ago, without a doubt the worst job to do on the thing. Access is very poor indeed to the top bolt. I ended up bending a spanner to a special shape and getting an extension (jack handle) to get it to undo.

Third gen may be easier, i certainly hope so for your sake. I ended up with blood all over and never want to have to do another one as long as I live.
Al.

[solent_surfer]

Cheers Al, got a feeling i might end up doing the same. It's right up against the firewall. Cheers for the pointer though

[rodthrutheblock]

Whipped (ha ha) the starter out of my 2nd Gen and the top bolt was a git too. I bent a spanner and eased it out a mill at a time. It looked so bad I was going to plasma a hole in the passenger footwell and do it that way........no, really. I was. At least it would be easier the next time.
It will come. Have regular cups of tea and make sure the nut spins up the bolt with a bit of oil like a rat up a drain pipe for reassembly. Makes it a whole lot easier. Better to nip up the last bit than have to do the whole agonising process in reverse.
You can actually get a flexible socket drive extension made from a tough rubbery stuff which should give bend to the 'S' shape you need to get it round the footwell to get a ratchet on it.

[TonyN]

Ratchet spanners are your best friend.

[Bracpan]

Done my starter last night, started at 7 finished and re-started the Surf at 9-15. Was a bit of a fidle to get out but once done went back in less than 15mins.
I jacked it up, took the neraside wheel off, then the rubber covers so I could see the bottom of the starter. Next I undone the bottom nut & bolt and removed it. The I took the Autobox dipstick pipe off and uncliped the ajoining cable. I could then see the dreaded top nut on the starter. I managed to loosen it with a open ended spanner then got a socket and 2 extention bars on it to loosen it a bit more. ( I then disconected the battery and the main conection onto the Starter) It was a slow but steady job of removing the top nut. I then looked down from the engine compartment to undo the small cable from the top off the starter, bit fidly as its a clip type but it came out ok in the end.
Then the problem of removing the now free starter, It would not go down past the Chassis so I undone one small pipe that ataches to the manifold, and undone the clip than held it to the oil filter mount. I spread the remainign pipes as far apart as possible the carefully and slowly pulled the motor up just missing the oil and fuel filters until it was up and free. This would have been much easyier with 2 people as one under slowley pushing the motor up would have been better than trying to grip an oily heavy starter.
After that it was a job of cleaning the motor and replacing the conections as instructions stated that came with the Kit from Roughtracks.
It was then a matter of doing it all in reverse but only took about 15mins as it was very easy to drop it back down and conect it all up. Job dune... not easy but having worked on Minis for years not that hard either. Also done an inner CV Boot last week this was easyer than I thought to. Hope this helps
Phil

[phoebelala]

Done my starter last night, started at 7 finished and re-started the Surf at 9-15. Was a bit of a fidle to get out but once done went back in less than 15mins.
I jacked it up, took the neraside wheel off, then the rubber covers so I could see the bottom of the starter. Next I undone the bottom nut & bolt and removed it. The I took the Autobox dipstick pipe off and uncliped the ajoining cable. I could then see the dreaded top nut on the starter. I managed to loosen it with a open ended spanner then got a socket and 2 extention bars on it to loosen it a bit more. ( I then disconected the battery and the main conection onto the Starter) It was a slow but steady job of removing the top nut. I then looked down from the engine compartment to undo the small cable from the top off the starter, bit fidly as its a clip type but it came out ok in the end.
Then the problem of removing the now free starter, It would not go down past the Chassis so I undone one small pipe that ataches to the manifold, and undone the clip than held it to the oil filter mount. I spread the remainign pipes as far apart as possible the carefully and slowly pulled the motor up just missing the oil and fuel filters until it was up and free. This would have been much easyier with 2 people as one under slowley pushing the motor up would have been better than trying to grip an oily heavy starter.
After that it was a job of cleaning the motor and replacing the conections as instructions stated that came with the Kit from Roughtracks.
It was then a matter of doing it all in reverse but only took about 15mins as it was very easy to drop it back down and conect it all up. Job dune... not easy but having worked on Minis for years not that hard either. Also done an inner CV Boot last week this was easyer than I thought to. Hope this helps
Phil

Clearly you have a different truck to the 2.4 that I did. There was NO CHANCE!!!!!!!!!!!!!! of getting a socket on the bolt head, NO WAY NOT NO HOW!!!! Unless one decided to cut the bulkhead out first of course.

What model/engine are you describing?

[Derek T M]

Yo, 2.4 starters.... **%$£@> terrible job, had to do mine twice!!

The top bolt can be done with a socket an lots of extensions by going in above the gearbox crossmember, you also need a universal joint to get the angle.
I could'nt undo the wires until the motor was half out. Took most of the day 1st time, a couple of hours the second. Hope I never have to do one again.


Derek

[Bracpan]

Thats right a socket universal joint and 2 extensions....this only helped to loosen the bolt the rest had to be done with a open ended spanner slowley removing it bit by bit. Was not easy but not impossible either. But I do take the point that the 2.4 might be even tighter than the 3 litre which I have.
Once it was cleaned putting it back on was very easy as you could turn it by hand and only had to use a spanner for the final tightning....Sounds like my 2 hours 15 mins was a good time for the first time. I also losened the small wire once the starter was unbolted.
Best of luck
Phil