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?

 

Boy, I coulda used this last week when I had to do my 1999's! But honestly it wasn't too hard to figure out. Like you said, that top bolt is a total PITA and I cannot see it being possible without taking the wheel off for access.

Nice write up and pics!

 

an air- ratchet 3inch 3/8 drive extension, 3/8 impact wobbler, and 3/8 drive 13 mm impact wobbler will get the job done too... after you do about 10 they are a breeze... as a side note close your eye when trying to break it loose its easier... go figure...

 

Yeah you can do it in less tools if you have to correct ones. I used what I had. I have taken it off twice now. The first time took me about 2.5 hours to figure out how the heck to get that top bolt off. Second time took me 10 minutes tops.

 

Thanks man works awesome

 

Just got done taking mine out. Wow what a crap *** place to put that top bolt. Couldn't they have made it a stud? I wonder if it would hurt anything if I replaced that top one with a stud and nut?

Thanks for the write up. This would have taken much longer had I not had the heads up.

 

It won't hurt and thing considering the amount of these starters I see where some lazy *** left out the top bolt. Would a stud really make it and easier? A nut would be harder to start then the bolt and you have to tighten both...

 

Where is the negative cable (coming from battery) supposed to be connected at the starter?

 

The negative cable is a ground, it grounds to the frame of your truck/car.

 

this may seem a little silly but on the new recon starter what are the two holes with the black tabs/ inserts on the side of the starter for?

 

For me it was easier to get the top bolt out with a 3/8 straight extension and ratchet directly above the starter. The long extension and universal put me dangerously close to brake lines.

 

Hi im new to this site i wish i checked online before i tried to change this starter. but i was able to get the Top bolt off with a 1/4 -13mm socket, 1/4 -3"or small extension,1/4 ratchet and it worked on my 04 5.4 lariat.