Very Frustrated

ernie1 wrote:
Just curious about what makes this solenoid so difficult to replace once the starter is removed from the engine. Not disagreeing but I was thinking about how I used to remove the solenoid from my GM and Ford products and either install a new solenoid or sometimes just refinish the surface of the copper ring on the end. Are these starters different somehow? Yes I understand that not everyone wants to go to all this trouble especially if they are traveling. Was just thinking the fix could amount to either nothing or just the cost of a new solenoid.

The key to this is the fact that you really, really must want to replace just the solenoid.

To replace the solenoid, you MUST remove the starter.

Unless you have attempted this on the modular engines (or any aluminum block) you simply will not fully understand the work you will go to to remove the starter.

On this design, the bolts holding the starter in place are very close to obstructions making getting a socket firmly and squarely on the bolts a real challenge. I believe Ford has some special tools for this..

I can attest to the fact that unless you modify your socket (grind down the outside) to fit squarely on the bolt head, you most likely will round it off.

I can attest that the aluminum block and steel bolts just don't backout easily without binding. Aluminum and steel are not the best of friends and then you add in water and in my case salt water form winter ice removal and you now have the perfect thread locker.

I asked the mechanic that replaced mine how they were able to do the job... He pointed to a pile of extensions and told me that they use enough extensions to go out the front of the grill and bumper..

Once you go through this hassle, you may as well not only replace the solenoid but regrease/replace bearings, replace brushes, dress the commutator and the Bendix while you are at it.. You really do not want to have to revisit removal again.

By the time you buy all the parts, put several hrs into refreshing the entire starter, you will have more cost than just replacing the starter and solenoid as a whole the first time. And heck when you can get a fully refurbed starter/solenoid with some sort of warranty for $80 why bother tearing it apart yourself?

I really don't understand why the stubbornness of just wanting to replace one single part on the starter, when the solenoid goes bad, I can assure you the bearings will need serviced, the brushes will be worn and the commutator will need dressed..

Nothing like fixing this half you know what..