Changing Starter - Defender Source
Defender Source  

Go Back   Defender Source > Defender & Series Technical Discussions > Defender Technical Discussions


Reply
 
Thread Tools
  #1  
Old January 21st, 2008, 06:06 PM
mdmccallum's Avatar
mdmccallum
Status: Offline
Mike
'97 Defender 90 SW
Member
 
Join Date: Dec 2003
Location: Durango, Colo.
Posts: 425
Changing Starter

Anyone have any tricks to getting to the upper allen bolt? I can't get the hex key in since I can't see the damn thing.
Reply With Quote
Sponsored Links
Advertisement
 
  #2  
Old January 21st, 2008, 06:18 PM
JSQ's Avatar
JSQ
Status: Offline
Jack Quinlan
Member
 
Join Date: Jan 2005
Location: Leucadia, CA
Posts: 582
Make sure you're using a 8mm 3/8" hex socket with a breaker bar rather than some kind of key.
Your life will be much easier.

Preparatory application of PB Blastr will also help.
Reply With Quote
  #3  
Old January 21st, 2008, 06:22 PM
Andrew Vick
Status: Offline
Andrew Vick
95 D90
Member
 
Join Date: Feb 2004
Location: Basalt, USA
Posts: 437
Don't remember the sizes, but mine was a different size than the bottom ones.
Reply With Quote
Sponsored Links
Advertisement
 
  #4  
Old January 21st, 2008, 06:42 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,625
Registry
You should be able to get to that one from above. That or with a long extension and universal joint on the end, come in from the front side of the engine.

hth
charles
Reply With Quote
  #5  
Old January 21st, 2008, 07:30 PM
mdmccallum's Avatar
mdmccallum
Status: Offline
Mike
'97 Defender 90 SW
Member
 
Join Date: Dec 2003
Location: Durango, Colo.
Posts: 425
Quote:
Originally Posted by Andrew Vick
Don't remember the sizes, but mine was a different size than the bottom ones.

Oh No.

Are the rest of you finding this to be true?

I am using the 8 mm hex for both but I can't see the upper bolt to even no if it is correct.
Reply With Quote
  #6  
Old January 21st, 2008, 07:51 PM
Andrew Vick
Status: Offline
Andrew Vick
95 D90
Member
 
Join Date: Feb 2004
Location: Basalt, USA
Posts: 437
The upper was smaller, and it took forever to figure out. I thought "there's no way the upper bolt would be different", and sure enough, it was. Try going down a size.
Reply With Quote
  #7  
Old January 21st, 2008, 08:30 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,625
Registry
Ditto on the hex socket, but on both my trucks, the top was the same size as the bottom.

charles
Reply With Quote
  #8  
Old January 21st, 2008, 09:54 PM
JSQ's Avatar
JSQ
Status: Offline
Jack Quinlan
Member
 
Join Date: Jan 2005
Location: Leucadia, CA
Posts: 582
They are both 8mm.
Reply With Quote
  #9  
Old January 22nd, 2008, 12:31 AM
bjenk
Status: Offline
Brian Jenkinson
1994 D90
Member
 
Join Date: Oct 2004
Location: morrison, colorado, usa
Posts: 158
Be prepared!!! this was the hardest repair of my 90 yet...I just kept telling myself "Two Freak'n Bolts, nothing more, nothing less...
I stripped the hex (oh I blasted it for a couple days with bp), used a dremmel and slotted the head and it stripped, Cut the bolt head off....ha the starter was out...Bp blasted more. Started to get the studs outs, one came out the other broke right at the housing. I drilled out the bolt and the bolt extractor broke off inside the bolt...I ended up getting a very expensive drill bit (robinson bit) and was finally able to drill through and put a nut on the other end...
I was besides myself the entire time and would lay under there looking at those bolts for hours.
Good Luck with it.
Reply With Quote
  #10  
Old January 22nd, 2008, 12:16 PM
Emerson00
Status: Offline
Matt J.
None at the moment
Member
 
Join Date: Dec 2006
Location: Maryland
Posts: 401
Great.

Replacing my starter happens to be my project for Saturday morning. The starter was just delivered yesterday afternoon.

I will attempt to keep my whining to a minimum.
Reply With Quote
  #11  
Old January 22nd, 2008, 05:59 PM
MonLand
Status: Offline
Loic Fabro
95 D90 - 96 Disco -06 LR3
Member
 
Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
Registry
Quote:
Originally Posted by bjenk
Be prepared!!! this was the hardest repair of my 90 yet...I just kept telling myself "Two Freak'n Bolts, nothing more, nothing less...
I stripped the hex (oh I blasted it for a couple days with bp), used a dremmel and slotted the head and it stripped, Cut the bolt head off....ha the starter was out...Bp blasted more. Started to get the studs outs, one came out the other broke right at the housing. I drilled out the bolt and the bolt extractor broke off inside the bolt...I ended up getting a very expensive drill bit (robinson bit) and was finally able to drill through and put a nut on the other end...
I was besides myself the entire time and would lay under there looking at those bolts for hours.
Good Luck with it.
I feel the pain.... Now I am glad I was luckier..... The top bolt is accessed from the top. Mine was PB'd for two days every two or three hours to no avail. Tried to heat (hot enough?), could not attach a wrench, ended up cutting the head with a small 4" grinder (perfect size). Took roughly 4-5 hours (between going to the local Home Depot to get that "advance gas" cartbridge and other pliers / wrenches / etc. to try to get it out. Now, I'd just cut the bolts.

Both bolts were the same size on my '95 D90.
__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
Reply With Quote
  #12  
Old January 22nd, 2008, 09:57 PM
mdmccallum's Avatar
mdmccallum
Status: Offline
Mike
'97 Defender 90 SW
Member
 
Join Date: Dec 2003
Location: Durango, Colo.
Posts: 425
So were both bolts difficult for you guys? I got the bottom one out but couldn't even engage the top one to try. I put everything back together and I am driving it again as is.
Reply With Quote
  #13  
Old January 25th, 2008, 10:25 AM
Antichrist's Avatar
Antichrist
Status: Offline
Tom Rowe
Defender/Disco/Series/MoD
Member
 
Join Date: Feb 2006
Location: Atlanta, GA USA
Posts: 1,280
Both the same. The top one is done with a long extension so your ratchet handle is near the front diff.
Attached Thumbnails
Click image for larger version

Name:	starter_bolt.jpg
Views:	151
Size:	26.1 KB
ID:	11834  
__________________
Tom Rowe
Atlanta, GA

Four wheel drive allows you to get stuck
in places even more inaccessible.

62 88 Regular
67 109 6cyl NADA x2
74 Lightweight - The Antichrist
95 DI 5-speed
95 D90 5-speed
97 D1 Automatic
Reply With Quote
  #14  
Old January 25th, 2008, 10:33 AM
Emerson00
Status: Offline
Matt J.
None at the moment
Member
 
Join Date: Dec 2006
Location: Maryland
Posts: 401
Tom,
Is that the same setup as on your '95 D1? That should be similar to the RRC of the same year, yes?
Reply With Quote
  #15  
Old January 25th, 2008, 08:53 PM
Antichrist's Avatar
Antichrist
Status: Offline
Tom Rowe
Defender/Disco/Series/MoD
Member
 
Join Date: Feb 2006
Location: Atlanta, GA USA
Posts: 1,280
Not sure about the RRC. That's an illustration from the Discovery manual, but I used the same tools on my Defender.
__________________
Tom Rowe
Atlanta, GA

Four wheel drive allows you to get stuck
in places even more inaccessible.

62 88 Regular
67 109 6cyl NADA x2
74 Lightweight - The Antichrist
95 DI 5-speed
95 D90 5-speed
97 D1 Automatic
Reply With Quote
  #16  
Old January 28th, 2008, 09:30 PM
cgalpin's Avatar
cgalpin
Status: Offline
Charles Galpin
'94 D90 ST, '63 SeriesIIA
Site Team
 
Join Date: Jan 2004
Location: South Riding, VA
Posts: 11,625
Registry
So how did it go?
Reply With Quote
  #17  
Old January 29th, 2008, 10:18 AM
mdmccallum's Avatar
mdmccallum
Status: Offline
Mike
'97 Defender 90 SW
Member
 
Join Date: Dec 2003
Location: Durango, Colo.
Posts: 425
If you are talking to me, I haven't attacked it again. Its been snowing so much that all I do is shovel my driveway and ski. Mostly the latter and my driveway shows.

My 90 still starts but every 3rd start or so it just whines instead of turning over. I stop cranking it and start again and it usually turns over. Its like something is sticking in the starter.
Reply With Quote
  #18  
Old January 29th, 2008, 10:29 AM
Emerson00
Status: Offline
Matt J.
None at the moment
Member
 
Join Date: Dec 2006
Location: Maryland
Posts: 401
Mike, I did manage to get mine out. Having read this thread, I was really careful about that top bolt. The diagram Tom posted did work for me as well, though not as much for the upper bolt.

I took my time blindly finding the top bolt with the hex/allen socket with an extension. Tapped it firmly into place and then pt the ratchet on it with a 2.5 foot pipe on the ratchet. It broke free first try though only at the extreme end of the ratchet's available arc. I thought I was screwed when I heard the CRACK! Even then, I first thought I spun the socket in the bolt head...

I spent 10x the time planning the position and make-up of the wrench I would use as I did backing the bolt out. I loaded it up real well with PBlaster shot through the exhaust manifold beforehand; perhaps that helped, too.

It was also an 8mm
Reply With Quote
  #19  
Old January 29th, 2008, 11:07 AM
Devin W's Avatar
Devin W
Status: Offline
Devin Walton
None
Member
 
Join Date: Oct 2006
Location: Fort Collins, Co, USA
Posts: 76
Both of my bolts were the same size, too. Although I could reach the top bolt from the top, at one point, I felt that it was starting to round out, so I just pulled the manifold to avoid the hassle of a stripped bolt head. Fortunately all of the manifold bolts were far easier to work with than the stupid starter bolt and it took the frustration factor down significantly since I could more easily access the bolt securely.
__________________

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Reply With Quote
Reply

Lower Navigation
Go Back   Defender Source > Defender & Series Technical Discussions > Defender Technical Discussions

Tags
start, starter

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Starter issues on my D90 Rover- Girl Defender Technical Discussions 13 February 13th, 2010 10:59 PM
Compatible starter motor question? MiniGuy Defender Technical Discussions 14 January 3rd, 2006 10:58 PM
Starter solution for TD D90? torque Defender Technical Discussions 0 April 30th, 2005 11:10 PM
Starter going bad? loykd Defender Technical Discussions 6 September 15th, 2004 10:12 PM
Fun new problem: starter circuit issue jaherring Defender Technical Discussions 1 September 12th, 2004 03:07 AM


All times are GMT -5. The time now is 08:18 AM.


Copyright