I went to replace the starter on the Maverick 200 and the top bolt near the block apparently is an alien. Someone apparently trashed the threads in the bell housing and used a bolt from the front and a nut on the rear. Both are literally froze and the only way I can see now is to cut the head from either one, remove the starter and punch out the remaining piece of the bolt. This is is very tight confines. Any suggestions on tool would be greatly appreciated.
i think i replyed to your fordsix ost too but here it is again get the chraftsmen damaged nut/bolt removal set. its a 5pc set. mine was on sale for $15. it was the only thing that got my starter out and i tryed every hand tool in my arsenal. it does kill the bolt so be prepared to buy new ones.
Well, I got lucky! I kept working the bolt back and forth and finally got it free from the nut placed on the end in the back of the bell housing. The moron put a NF nut on the NC bolt. I was concerned that the threads in the boss of the bell housing were trashed but after chasing the threads using a tap, they apparently were not affected. the Threads on the end of the bolt were trashed so into the recycle pile. What idiots we have working on cars! Now for a question for all. How long were the original starter bolts and did they have lock washers on them? I will take the starter to get it rebuilt tomorrow and will acquire new hardware.
i have taken my starter off twice.. the bolts are maybe 1in. long (do not use this, cause im not sure). mine do not have lock washers on them..
my 250 ones had the lock washers. but the 250 uses the same starter and bellhousing as the 302 so it may be a diffrent size and setup on the 200
Typically Ford starter bolts us a flat washer and a bolt that is 1 1/8" long. Using a lock washer on the aluminum housing of a starter is not a great idea. The flat washer will keep the bolt from backing out and if the bolt is loose and won't stay in then use a bit of Loctite "Gasket Maker" on the threads. It hold well and removes easier than thread lock.
Actually, the lock washer is on the starter housing side so that is steel. I was concerned about length to ensure there was enough shank going into the threaded boss on the housing and the possibility of the bolt backing out. the bolts that were used looked to be on the short side.
ok, you said you were gonna get the starter rebuilt? how much does that cost? cause i got a new one from napa for $45..
I rebuild my own starters. As long as you don't have to replace the brushes - which is normal- all you need to do is clean the case and housings, turn the armature, set the brushes and set the contacts to open. Paint and use. All my starters have aluminum front housings... are you sure yours is steel?
I usually go the GenStar which rebuilds starters, generators, alternators, etc. in lieu of buying an assembly line rebuilt one. These guys have been in business for eons and do the job right. I have not gone there for many years so I will check first on the price. It might be better to just get a new one from NAPA. I will check the housing again to see if it was aluminum or steel as it was very dirty. The lock washer issue is not critical. I am keeping my fingers crossed that there is not going to be any more wiring issues that I also had to solve. Someone screwed up the wiring when a stereo was put in and I also found a homemade butt plug patch from the A/C compressor. The gauge of the wire was not proper and I will have to replace it later.
