Torque'd the starter stud right out!
 

Well I almost did it, almost got the engine and transmission put back together without a misstep. Almost.<p>I installed a mini hi-torque starter as part of the whole project, and as I was torque-ing the engine to transmission nuts (30ft.lbs.) I noticed the second starter barrel nut seemed to take longer to torque than the others. Something wasn't right. So I undid the barrel nut, along with the top barrel nut and tried to take the starter off to see if something wasn't seated right. This is what happened:
http://forums.pelicanparts.com/uploa...1318551339.jpg

The whole stud came out, leaving this:

http://forums.pelicanparts.com/uploa...1318551418.jpg

So I took this:

http://forums.pelicanparts.com/uploa...1318551491.jpg

Ground it down to this, to fit in the back:

http://forums.pelicanparts.com/uploa...1318551568.jpg

And installed it like so:

http://forums.pelicanparts.com/uploa...1318551773.jpg

I know this wouldn't be the optimum fix; but torqued to spec, does anyone see an immediate reason why this wouldn't work?<P>Oh, and if I've learned anything in the last hour, it's that I've eaten cheeses harder than freaking magnesium. Thanks guys!

Looking at the pics, has that mounting "ear" been cracked / split and TIG welded for repair before ?

Looks like a good fix.

Doesn't your bell housing look like it has been welded upon? Including where this stud went? It looks like that repair included a Helicoil or something with a similar function, which backed out or pulled out.

Several of my engines have had a Helicoil where the engine studs are held to the engine case. I don't know if that is factory standard, or indicates a repair. All have worked fine for me, happily.

Oh man HWM! Sorry to see that brother!

Glad you rigged somthing up to cure it. Lucky it was the bottom on e not the top, it would be a complete biotch to service the starter in the future if it was the top barrel nut.

Jim

Yeah, that's exactly what it looks like to me too. You can see the weld go all the way around the mini "bell housing" for the starter. It was quite the surprise for me the first time I dropped the engine and tranny, that big weld line.