starter motor query
 

So I was resurrecting an old failed starter - had chewed the drive gear out - failed clutch. Fitted new clutch but then I see something seems to be missing.
Is it a bush or bearing? Went to my local auto elec shop and they can't pull a part up for this end housing assembly.
Off an aircooled 911 1970s-80.
Thanks
Alan

http://forums.pelicanparts.com/uploa...1709517812.jpg

maybe the wrong gear installed on the starter?
look
https://dz310nzuyimx0.cloudfront.net...b8d3ddcc16.png
here is mine spare..
http://forums.pelicanparts.com/uploa...1709551851.jpg

I measured the gear/clutch/shaft against the old one. Identical.
Your parts pic is helpful. It seems to be showing a bush (#6). I suspect that is what I need. My auto elec guy pulled up the starter Bosch # and could not find such a part. But I think that is what I need - #6.
Now, how to find one.
You can see the punched ends on the housing - mine and yours. They seem to be holding a retainer for the bush. I am missing those bits.
Thanks
Alan

OK - further googling and I am missing a pinion gear bronze bushing.
Anyone know where to source parts for these starters?
I have drawn a blank so far.
Other than they are a Bosch code DEF 76-81 type starter.
Thanks
Alan

Replaced my starter with a Wosp denso style starter from our host. Took my old starter down to auto electric shop to have it rebuilt as a spare. He cannot get parts to rebuild. Armature was worn out.
I had to replace heater hose for new starter old one was too short.

Curious what diagram proporsche posted, as it doesn't seem to be a 911/912/914/944 one :D

Stoddard list a "NLA-604-016-00 12 Volt Starter Bushing 911 1965-73" replacement for 90160401600 - but nothing for the later cars.

Probably a reasonable SWAG that it was a bushing. If your housing/shaft are not too beat up, should be able to get good dimensions off them to make a replacement? Apparently SOP for the 356 guys is to remove theirs with a 9/16" tap, which may be why you don't have one anymore...

356 registry guys say that Stoddard's 6V starter bushing is oversized by .001" (@ 0.651"), and suggest other sources - like VW ones. Might be another place to look.

yah ,the diagram was just a helper...to point out the gear..
Ivan

Alan,

Looking at my spare Bosch starter, the part you are missing appears to be a seal.

http://forums.pelicanparts.com/uploa...1709745143.jpg

It's a support ring/bushing. It's probably sitting down in the bellhousing. I had one come loose from a rebuilt bosch starter and jam the flywheel. Had to remove the engine to get it out. Those little swage divots are supposed to hold the ring in place.

Hi John - mine went down the bellhousing too.
I have already had this motor out twice in the last couple of weeks. Spent hrs fishing bits out - including a bit of the bush.
Yes - there is a seal in there too - next to the bush.
I am, going to make one up (I have a lathe). Got a lump of bronze bushing on order.
https://www.bearingandengineering.co.nz/shop/BEARINGS/Bushes/Bronze.html
Thanks
Alan

Check your ring gear too. I went to a high torque starter after bad luck with a couple of Bosch starters.

Yeah - the ring gear is OK. Not pristine, but OK.
That starter actually tore the drive gear to pieces - when the starter clutch failed. It did a bit of damage to the ring gear but it is Ok. The starter came off worse. I fitted a new clutch unit to it and new drive gear, and now it has fired the end assembly out. Hard to figure. The travel of the pinion is a fixed distance and stops about 1mm short of the end housing. Anyway, we push on. Will make a new bush. I just want it as a working spare - since I have two cars utilising the same type starter.
Thanks
Alan

So all back together now. I made a new end plate cover - the old one got a bit mangled in the bellhousing. Maybe useable - I did some panel beating on it then decided just to machine a new cover.
It is all working fine now.
A lathe is the best tool you can have in the workshop.
Alan
http://forums.pelicanparts.com/uploa...1710106086.jpg
http://forums.pelicanparts.com/uploa...1710106142.jpg
http://forums.pelicanparts.com/uploa...1710106206.jpg

excellent...

Of course I could have just purchased a new one. But I currently have a new one back with the supplier - it fails regularly. The pull-in curent for the solenoid is higher than my loom, and my bench test likes. On the other hand, my old starters work just fine - on the bench and with the existing wiring loom.
So it is worth keeping them if possible.
Alan

Nice fix Alan, looks great.

Thanks.
It has made use of something that was destined for the bin. For a few $s (cost of a bronze blank) and some time in the shed. And it seems more reliable than the new one I had in reserve - which has gone back. Sometimes the old original bits are just better and worth hanging on to.
Alan