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Thu Apr 21, 2011 10:58 pm

Bear with me as I blab and give you some back story here. I'm gonna start by saying that I am no mechanic by any means but I do what I can. I recently got a 66 beetle. The previous owner told me that before they garage it 7 years ago that the starter was acting up on them. Only in the last 2 weeks have I seen any problems with it not starting so it became irritating and I decided to change it out. Went to autozone and they set me up with a new one. When I started her up, it would hit real hard and it turns out that the drive was bad. Swapped it out for another. The second one they gave me had a bad solenoid. It would give me one click when I turned the key. Went and swapped it for a third, they tested it in store and it worked fine. Get it home, set it up and get the hard banging sound again. Them after about 3 starts, it now won't even turn over, just get a single click. NOW, I can't get it off! I unplug it and take the bolts out and it won't even wiggle. After the second starter failed on me, I put the old original back on and it worked fine. I did that to rule out a problem with the car itself. so, any ideas of how to get this new starter off? And I doubt I've been screwed by 3 new failed starters...but any ideas there....? Anything helps....thank you

Fri Apr 22, 2011 12:16 am

Let's start with more info about your car...is it still 6 volt or did someone convert it to 12 volts? As for you're starter problems..did you replace the starter bushing that's in the transmission case? Did you put a bit of grease in the bushing? Now go read this link and follow the test to figure out what other starter problems you're having.

http://www.vw-resource.com/starter.html

Fri Apr 22, 2011 12:30 am

12 volt. And no

Fri Apr 22, 2011 12:39 am

That little bushing is very very important to the correct operation of a vw starter. It must be changed and greased every time you replace the starter. The easiest way to remove the bushing with the motor in is use a tap that's just larger than the inside diameter of the bushing. Twist the tap into the bushing until it's in nice and tight, then wiggle and pull on the tap until the bushing comes out. Installing the bushing takes a little care because you don't want to smash or bend it. If you get it started with your fingers you can usually tap it in with a small piece of wood until it's flush with the transmission case. Put small dab a grease inside the bushing..install the starter and you'll be in good shape for many miles/years.

Fri Apr 22, 2011 12:45 am

Thank you autozone management for telling me differently. Ok I can do that....but my other problem is that I can't get the damn thing off. Everything loosened and the starter won't wiggle. I'm about to beat it with a hammer to see if that helps. Any ideas? Do I need a tool together the bushing in and what about the old one, how do I get it out?

Fri Apr 22, 2011 12:51 am

Gently rotate the motor (by hand)...the starter is likely stuck on the flywheel. It should free up if you rotate the motor one direction or the other. One last bit, you'll need a 6/12 volt bushing. It's a bushing that fits into a 6 volt transmission, but has the smaller inside diameter for the 12 volt starter shaft. If someone gives you the wrong one you'll still have problems.

Fri Apr 22, 2011 12:54 am

The starter came with one, can it be used? Is there an old one that needs to be taken out cause nothing came out when I took out the old starter. Another question for ya....would doing this with the bushing stop the hard clanking sound when it turns over with the new starter?

Fri Apr 22, 2011 12:57 am

The one that came with the starter should be correct. You need to look into the hole the starter came out of to see the bushing...it's on the far side pressed into the transmission case. It will not come out without some help....use a tap from a tap and die set. I'll go get you a picture if you hang on a minute.

Fri Apr 22, 2011 1:02 am

The bushing is inside the hole you can see the starter shaft in. With the motor out you can remove/install the bushing in either direction.

Fri Apr 22, 2011 1:05 am

The transmission case is broken in this picture, so it allows you to see the little brass bushing inside the trans case.

Fri Apr 22, 2011 1:08 am

Ok. So should this eliminate the hard clanking sound I was getting?

Fri Apr 22, 2011 1:09 am

This is what you need to remove the bushing. The bushing is still on the tap in this photo.

Fri Apr 22, 2011 1:12 am

Yes...Once you replace the bushing and use some grease your car should start without clanking, clicking, or grinding. If it does you have other problems.

Fri Apr 22, 2011 1:41 am

THank you! I'm headed home now to give it a shot

Fri Apr 22, 2011 2:32 am

Any comment on why the old starter doesn't have a bushing and why the new one doesn't fit in the hole? And why the bushing that came with the new starter fits on it, but not on the old starter?

Fri Apr 22, 2011 4:18 am

Simply buy an autostick starter & forget about the bushing. Another thing, don't buy aircooled parts from FLAPS.

Fri Apr 22, 2011 4:21 am

There are different bushings with different inner and outer dimensions depending on whether the bushing is for 6 or 12 volt, and then there is also a hybrid 6/12 bushing.

It make take an extra day, but you should just save yourself the headache and get an autostick starter. It is self supporting and doesn't use a bushing. Just ask for a starter from a later (maybe 74 beetle) and specify "autostick", they may have to order it though.

Also, I know you said the car is 12 volt, but are you sure the engine has a 12 volt flywheel? Sometimes people do a 12 volt conversion and leave the old 6 volt flywheel on. They then change the solenoid on the starter to 12v but use the old 6v starter body. The teeth on the starter MUST match the teeth on the flywheel.

edit: haha, Gimpy beat me to it! I got slow fingers

Fri Apr 22, 2011 4:57 am

Flux is right, your car may be bastardized beyond repair.........it happens. Do look at the old one & compare it with what you been gettin from the idiots at AZ. Visual diff. between 6 & 12v. drive gears. Good luck!!!!!

Fri Apr 22, 2011 8:39 am

Ok...pulled out the tape measure and the old starter drive is larger than the new one. So does that mean I have the 6 volt flywheel in there? So now what? Explain the autostick to me, is this what I have to do?

Fri Apr 22, 2011 9:00 am

dzeak7 wrote: Ok...pulled out the tape measure and the old starter drive is larger than the new one. So does that mean I have the 6 volt flywheel in there? So now what? Explain the autostick to me, is this what I have to do?

Aside from measuring the flywheel or counting the teeth on the flywheel, I don't know of any tricks to tell you exactly what you need. Maybe somebody else knows a trick by the measurement of the gear on the original starter (but I don't know much about the 6v stuff).

As for the autostick starter, I think this is only going to work if you do indeed have a 12v flywheel.

It's just like the other starters, except it's got some magic beans in it that keep the gear steady when in actuates. It doesn't need the extra guide rod/bushing at the end of the starter. The pic below shows two regular starters on the left and an autostick starter on the right to show you what I mean.