Well I recently had my starter hang up and leave me stranded for awhile about an hour away from home. As soon as I got it started I decided it was time to have it rebuilt. So here is my how-to right up as I didn't find any other instructions on it.

Items You Will Need:

3/8" Ratchet
13mm Socket
2 Short Extensions
1 Medium Extension

Air Wrench
1/2" Ratchet
13mm Socket
1 Long Extension
1 Short Extension
1 Swivel Extension

1/4" Ratchet
10mm Socket
(my pictures shows a few extra things, but this is the basics that you need)


Picture of Starter (note 3 bolt holes)


Step 1
Unplug your battery before removing this all. Make sure your engine is cool, the starter is located right next to the exhaust and oil pan.

Step 2
This step is optional, but makes it a lot easier to work. I removed the wheel from the front passenger side to make it easy for when you get to Step 4.

Step 3
First you want to remove all connections on the starter. Mine had a red plastic piece that you must pop off. There is one small connection requiring the 10mm socket, and then two that require the 13mm socket.
Here is all the connections after being removed.


Step 4
Remove the top bolt on the starter, it requires the 13mm socket. It's a total PITA to get to and remove, but easiest if it comes out first. My suggestion would be to reach your hand around the outside of the starter and feel for it. I then attached the swivel extension on the back of the socket. Then you have to run the one long 1/2" extension through the fender well and attach to the swivel extension. Then using the air wrench I loosened the bolt. (do not try to remove it all the way, you just want to break it loose)



I assembled roughly how it should look when its inside and on the bolt.


Once you have the bolt broke loose, you should be able to use the 1/2" short extension with the 13mm socket to remove it by hand the rest of the way.

Step 5
Now you will remove the other two bolts. One is located directly over the solenoid and the other is behind where you removed the ground wire. To remove the one over the solenoid you should use the 3/8" ratchet with the two short extensions and a 13mm socket. The bottom one should easily be accessible with just one short extension.

At this time you should be able to remove the starter and either repair it or replace it. To reassemble i would do those steps in the reverse order.




Hopefully this helps all with any starter issues.

 

Awesome job.
Thanks

 

No problem, hopefully it can help a few out.

 

I'm assuming this was a 2005, 5.4?

 

Yes it was, but it should be almost identical on any model 5.4 I would think. From different body style the engine shouldn't change much in relation to frame setup.

 

I agree, but when we put it in the Articles and How To section, it needs to be specific in case anyone has a question.

 

great job!!!

 

Gotcha .

 

The image links are dead. A pity too, I am trying to figure out how to get to the danged top bolt of my starter. The manual says there are 2 bolts, but it is plain that there are 3, and that top one is a SOB to get to...

 

Images are there for me?

 

All wires and 3 bolts are removed, but it still won't come out. what should I do now?

 

Hit it with a hammer.

 

Don't use rebuilt's, get a new one. cheap enough. http://www.ebay.com/itm/New-Starter-...-/291131827455