starter motor query

[Alan L]

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

[proporsche]

maybe the wrong gear installed on the starter?
look

here is mine spare..

[Alan L]

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

[Alan L]

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

[911obgyn]

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.

[spuggy]

Originally Posted by Alan L

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

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

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.

[proporsche]

Originally Posted by spuggy

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

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

[dkirk]

Alan,

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

[john walker's workshop]

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.

[Alan L]

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

[RSTarga]

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

[Alan L]

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

[Alan L]

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

[proporsche]

Originally Posted by Alan L

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

excellent...

[Alan L]

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

[Kraftwerk]

Nice fix Alan, looks great.

[Alan L]

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