Starter Won't Go In AFTER New Bushing

[srb]

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
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1988 Vanagon Wolfsburg

[Munroman]

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!

[FNGRUVN]

Are you sure the bushing fit to begin with?
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[Timwhy]

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

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.
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[srb]

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
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1988 Vanagon Wolfsburg

[Alaric.H]

There is a tool for that VW tool 222a.

[MarkWard]

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.

[srb]

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!
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1988 Vanagon Wolfsburg

[Timwhy]

[87vanagon]

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.
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Nick
1985 1.9L Vanagon GL- Daily Driver

[sc1out]

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.

[vanjoe]

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.

[tencentlife]

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.
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[sc1out]

[srb]

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...
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1988 Vanagon Wolfsburg

[Robbie Dog]

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?
_________________
Ladies and gentlemen, this tall drink of water headed my way is a pillar of the shopping community who informed me earlier today of a nefarious plan of his to screw my girlfriend in an extremely uncomfortable place.
What... like the back of a Volkswagen?

[srb]

@ 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!
_________________
1988 Vanagon Wolfsburg

[Robbie Dog]

Is there a poor mans tool to do the job?
_________________
Ladies and gentlemen, this tall drink of water headed my way is a pillar of the shopping community who informed me earlier today of a nefarious plan of his to screw my girlfriend in an extremely uncomfortable place.
What... like the back of a Volkswagen?

[Timwhy]