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Wed Jan 12, 2011 3:49 pm

Hello,
I attempted to replace my starter in an '88 Vanagon yesterday, but failed. I'm having a strange situation and am looking for feedback.

I removed the old starter, and while rushing, put the new starter in with the old bushing. It fit just fine—super easy to get in. Just after I tightened the bolts, I realized my mistake of using the old bushing.

So, I removed the new starter, got out a 7/16" tap and removed the bushing. Then, I put a new bushing in the hole, having to knock it in with what I thought was very light force. The bushing got in there flush with the hole, and then I attempted to put in—again—my new starter. The new starter will not go in!

I've rotated the teeth, angled it, pushed from below, pulled from above...just about everything I could think of for 1.5 hour before my arms gave out.

Is it possible that I somehow "shrank" the bushing when knocking it in? Should I have put the new bushing on the starter, then replaced both together? Is the bushing really that tight that it has to be an amazingly perfect fit?

I'm about to tap out that new bushing and try again with a second new bushing...I just can't think of what else to do, and I don't really have enough room to pound in the starter while under the vehicle.

Suggestions, please?

-Steven

Wed Jan 12, 2011 5:40 pm

Hi Steven, sounds like you have maybe put a flat in the end of the bush when you hammered it in, making the hole too small.

You could either try using a chisel or file to open up the very front of the bush, or removing the bush after checking that the new bush fits on the starter ok, then using wood between the bush and hammer when fitting the new bush.

If you soak the bush in engine oil for a while it helps both the starter and fitting.

I had starting problems when hot and found a burr where the mechanic who had fitted the starter bush had nicked it with a file or similar.

Good luck!

Wed Jan 12, 2011 6:03 pm

Are you sure the bushing fit to begin with?

Wed Jan 12, 2011 6:08 pm

Take your 7/16" tap and remove the new bushing and get a new one and start over.

Wed Jan 12, 2011 9:23 pm

on solid bushings like that, I fill the hole with greese then use a dowel or something similar that fits the hole. Tap the end of the dowel and hydraulic pressure will build behind the bushing pushing it out. Normally you can get it to pop out in one motion. If you need to stop and add more greese so be it. This will also not cause damage to the part that a tap might.

Wed Jan 12, 2011 10:03 pm

Thanks all.

The bushing fit the starter just fine in outside the housing. I must have inadvertently damaged the bushing when hitting it in. I thought I was gentle enough!

I'm going to remove the bushing and put in a new one shortly.

I figure it is best to start over.

Steven

Thu Jan 13, 2011 3:38 am

There is a tool for that VW tool 222a.

Thu Jan 13, 2011 12:40 pm

Or you can make a tool out of the upper starter bolt. Spin the nut down just enough so the bushing is flush with the end of the bolt. You can add a washer between the nut and the bushing, but don't drop the washer in the bellhousing. With the bushing on the end of the bolt centered in the bellhousing hole, light taps with a hammer until the bushing is flush. This should protect the end of the bushing. Good luck.

Thu Jan 13, 2011 12:47 pm

Thanks rsxsr. I will try your suggestion in combination with a bit of engine oil on the bushing itself.

I know that bushing is a tight fit on purpose, but it's no fun learning you've slightly burred the edge and it's damaged, while holding up a starter under the bus, pushing for an hour!

Thu Jan 13, 2011 2:43 pm

rsxsr wrote: don't drop the washer in the bellhousing

I was nervous that I would drop the bushing into the Bellhousing, so I stuffed a clean
rag into the small hole. Just enough to keep something from going down there.

Thu Jan 13, 2011 9:03 pm

I used a tap to remove the old bushing as you did, but to install the new one I got a wooden dowel and trimmed it down to the correct size and tapped it in with that. The bushing is copper so you need something softer than that so not to damage it. I first used this method on my 96 GTI and then again on my van, have had the same dowel for 2 years now.

Sat Jan 15, 2011 8:47 am

From a practical standpoint, not a purist, how important is it to replace the bushing if there are no known problems with the old bushing? The fit of the new bushing on the new starter does not appear to be that critical of a tolerance. The fit of the bushing into the tranny housing seems to be tighter tolerance than bushing to starter shaft. I am loath to pack that area with grease to pop out the old bushing if not necessary. Any opinons or experience of leaving the old bushing in?
thanks.

Sat Jan 15, 2011 10:49 am

I replaced my starter about 3 months ago and couldn't get my old bushing out because I was pressed for time. Mine has been working fine with no problems.

Sat Jan 15, 2011 12:04 pm

Mic the OD of the nose of the starter pinion, see if you can find a drill bit close in size but slightly larger, and use it to ream the bushing in place. If you don't have a dril size within, oh, .008" of the pinion size, just ream the entry to the bushing, that's probably where the burr is anyway that's making it hard to fit.

Sat Jan 15, 2011 5:24 pm

tencentlife wrote: Mic the OD of the nose of the starter pinion, see if you can find a drill bit close in size but slightly larger, and use it to ream the bushing in place. If you don't have a dril size within, oh, .008" of the pinion size, just ream the entry to the bushing, that's probably where the burr is anyway that's making it hard to fit.

Thanks. I will try to get the new bushing, starter shaft, and the old bushing MICed. I bought a wooden dowel that is only a few thousandths smaller than the new bushing and I am going to try the "pack it with grease" method of extraction. That would be a neat trick.
Pictures to follow late in the week!

Tue Jan 18, 2011 8:59 pm

Hello,
So I got a rat tail file and filed down the bushing (my local auto store took a week to get a replacement bushing, and I just couldn't wait any longer...). I finally worked the burr down and the starter made its way in.

For next time, I have a dowel waiting in the wings...

Tue Jun 07, 2011 1:02 pm

About to to this job, but struggling to get the old bush out , best method?? how hard should you have to tap it to get it out?

Tue Jun 07, 2011 1:12 pm

@ Robbie Dog:
You don't "tap it" to get it out...you use a tap which screws out the stuck bushing from the housing. Then, use a dowel to hammer in the new bushing, with just as much force as necessary. Then, fit in the starter.

Good luck!

Tue Jun 07, 2011 1:40 pm

Is there a poor mans tool to do the job?

Tue Jun 07, 2011 2:12 pm

Robbie Dog wrote: Is there a poor mans tool to do the job?

That TAP is a poor mans tool! Maybe a screwdriver to pry it down in the middle and then pull it
out? A buddy used a pick to push it in on itself an then it just fell out. Still think that the TAP is best!