Repair 7

How to Rebuild an Auto Starter

If you are handy with tools and want to keep down costs, instead of purchasing a brand new starter you can rebuild your existing starter. The most common causes of starter failure are worn-out brass contacts and a plunger that becomes too worn to properly engage the starter motor against the flywheel. Both can be be repaired with the use of a starter rebuild kit.

Instructions

1

Remove the starter from the vehicle. Methods for removing the starter will vary depending on the type of vehicle.

2

Purchase a starter rebuild kit from an auto parts outlet. These kits can be purchased for less than $40 as of 2010 and include most of the parts needed for rebuilding a starter. But you may have to purchase the starter plunger separately.

3

Find the end cover protecting the plunger and starter contacts. Disconnect the starter motor lead and remove this cover using a ratchet and socket or a Phillips screwdriver. This will expose the plunger and the brass starter contacts.

4

Pull the plunger out of the starter housing and set it aside. Take care not to lose the small spring at the end of the plunger. Find the L-shaped brass contacts on both sides of the plunger. Use a small box-end wrench to remove the retaining nuts holding the left and right contacts, along with the insulators and washers.

5

Install the new left and right contacts in the housing, along with all appropriate washers and insulators. Place the spring onto the end of the new plunger and feed the plunger into the starter housing. Tighten the retaining nuts with a box-end wrench. Push the plunger in against the spring to verify it pushes the starter gear outward. The gear should retract when releasing the plunger.

6

Reattach the end cover to the starter housing. Secure the cover with the three bolts and tighten them with a ratchet and socket or a Phillips screwdriver. Reinstall the starter in the vehicle. Methods for re-installation will vary, depending on the vehicle.