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I took the starter out to run the car.
So, I've never really heard of this, but my starter would not retract the starter pinion gear. I disconnected the solenoid to see if that would make it stop, but still it was being pulled along. I don't want to burn out the bushings so I couldn't drive it like that. Luckily I was with my buddy and we went to his house and got a few tools. I ripped the starter out and bolted the alt/batt wires together and we push started it. I haven't gotten into the starter, but I post what I find. I think that the gear is just physically stuck on the shaft.
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Joe, that's pretty common. The Bendix can either get stuck in and just spin...or it can get stuck out and get jammed in the flywheel or flexplate. A ruined ring gear is the end result if left unattended. There is no fixing the starter...not realistically...not unless you're a masochist. Just get a new one. It's done...
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I'm probably a masochist.... I pulled it apart... here's what I found. I saw a sticker for manufacturing. I checked our records and it shows a new one was put in in November of 99 at 87.5k mi. No one seems to remember having this done, but nonetheless, it's been done. I was under the impression that my year of car came with an older non-gear driven starter, if I's correct, then it looks like this one is a newer style one. Anyway, the damage is the plastic outer ring gear. It fell apart and broke in several places. Then rest seems to be in good shape. The brushes have an acceptable amount of wear for their age, but the commutator looks like only very minimal wear has occurred. If the ring weren't plastic I'd say that I have another 100k mi in this guy. Sourcing parts may be the snag. So now I'm off to price out a new starter, unless I find some readily available rebuild parts. |
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Well, I thought that it would be harder than I thought, but I rebuilt my starter for under $40. I figured that finding parts would be impossible, but Ebay had the solution. Triodiode had the parts to rebuild the starter. I confirmed with him that they would fit and they did. I needed just a new out planetary tracking gear and decided it would be good to replace the brushes. After shipping it was just under 30 bucks. I went the local university’s auto shop and borrowed their media blaster and painted later that day. To speed the drying up, after a half day of drying I stuck the parts in a toaster oven at about 200 degrees and for 45 minutes to speed the drying.
https://volvoforums.com/forum/attach...1&d=1326669050https://volvoforums.com/forum/attach...1&d=1326669050 Some starter info: This is the 1.9hp permanent magnet geared reduction starter by Bosch. It’s not the original one for this car. The original had no reduction and was rated at a lower hp. This is the later style that Volvo introduced with the DOHC red block from what I understand. My part number was 0 001 108 030. Volvo specifies 0 001 108 … as the part number for this starter. Now I will detail the reassembly of the starter. I cleaned and painted all parts prior. I started with the transmission. The output shaft and outer tracking gear are first. The tracking gear is the part that failed. I packed them with grease and slid the tracking gear over the end and put the large thrust washer over it too, with grease on all sliding parts. https://volvoforums.com/forum/attach...1&d=1326669050 Next I threw on the snap ring to hold it together. https://volvoforums.com/forum/attach...1&d=1326669050 I packed in a little more grease and put the cover plate onto the tracking gear taking note of the cutouts in the plate and lining them up with bolt hole pass-throughs. https://volvoforums.com/forum/attach...1&d=1326669050 |
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I put some grease on the twist splines next and slid on the flywheel engagement gear.
Then next part was the most difficult part in both disassembly and reassembly. There’s a funny snap-ring with another solid ring around it. I hit it with a screwdriver and hammer back towards the gear. The outer ring came off and then I spread the snap-ring with vice grips. So to put it back on, I put the solid ring on first and then the snap ring. Once it was in the groove I clamped it shut with the vice grips and ended up using a small puller to pull the outer ring over the snap ring. I had to hold the 3 jaws together and it started it on easily. Then I finished up with the vice grips. https://volvoforums.com/forum/attach...1&d=1326669297https://volvoforums.com/forum/attach...1&d=1326669297 I greased up the shaft and dropped it into the aluminum housing. The flat section of the tracking gear lined up with the open section of the housing. https://volvoforums.com/forum/attach...1&d=1326669297 Throw in the solenoid core with the spring and the rubber block next. https://volvoforums.com/forum/attach...1&d=1326669297 Then I put the solenoid coil one and only snugly fit the screws on. https://volvoforums.com/forum/attach...1&d=1326669297 |
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Slip the armature housing on next. Align the cutout with the rubber block.
https://volvoforums.com/forum/attach...1&d=1326669470 Before hand, I cleaned up the armature commutator. It was in pretty good shape already. It showed very little wear, but leveled it with a block and sand paper. It just took out any minor grooves. I finished with 2000 grit, but that was excessive. 220 to 400 to 600 is what I did before the 2000. https://volvoforums.com/forum/attach...1&d=1326669470 Before putting the armature in, it’s best to put the brushes on. The holder was a little misshapen, but I turned it so it would spread the brushes wider and it went over the commutator easily. https://volvoforums.com/forum/attach...1&d=1326669470 Then grease and throw the back cover on. Put the washer and c-shaped locking thing on with grease. Then put the cover on and the screws hold the cover to the back plate and the plate to the brushes. I left them a little loose. https://volvoforums.com/forum/attach...1&d=1326669470 Toss the whole thing in. My armature shaft was a little swollen on the transmission end so I filed and sanded it a bit to make it fit, earlier. https://volvoforums.com/forum/attach...1&d=1326669470 |
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Fit the long bolts (7mm wrench) through the whole thing. The magnets may interfere a bit. Snug them up and then tighten everything: the solenoid screws, the brush screws and the long bolts. Also put the commutator wire on the shorter and closer solenoid lug (13mm wrench).
https://volvoforums.com/forum/attach...1&d=1326669626 That’s it. It’s rebuilt. Put it on the car. The main bolts on the bell-housing are 19mm (which is ¾ in). Connnect the alternator and battery wires to the top lug on the solenoid and the Green and Blue striped wire to the outmost contact and it’s ready to run again! https://volvoforums.com/forum/attach...1&d=1326669626 Total time was probably under 10 hours, counting removal, installation, finding parts, fitting, cleaning blasting, painting, making this page and scratching my head. Cost was just under $38. |
Joe...God bless ya...but you're a sick, sick puppy!:D 10 hours and $40? It's been many years since I dismantled a starter; can't imagine doing it ever again unless there simply were no more to be had. Hopefully your PMR starter will hold up a while. They have a poor reputation for longevity compared to the older traditional units.
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Very nice!
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