Bronco 2 Starter Grinding

[wildbill23c]

It looks like the original 7/16x20 threads are mangled. The bolt that was in the top was much smaller then stock. By at least 1/16". I have it all apart right now. However, I don't have a 7/16x20 tap to chase the threads. Ill get one tomorrow and hopefully that will work. If not I got a thread insert kit today to but if the original threads are workable I would rather use those.

Looks like my Bronco gets to spend the night in the garage. That's a first. My squareback will have to spend the night outside, lol. My garage feels a lot smaller with my Bronco in it and not my VW. lol

Haha, yeah screwed up threads will definitely cause a problem trying to keep things nice and snug. Mine was always tight too when it would move, I'd still have to loosen the bolts to put the starter back in place, since getting new bolts I haven't had a problem. Sure hope the new bolts fix your issue as well. 2 bolts are far cheaper than an engine swap LOL.

 

[vdub]

Haha, yeah screwed up threads will definitely cause a problem trying to keep things nice and snug. Mine was always tight too when it would move, I'd still have to loosen the bolts to put the starter back in place, since getting new bolts I haven't had a problem. Sure hope the new bolts fix your issue as well. 2 bolts are far cheaper than an engine swap LOL.

True, but the 302 isn't primary to fix this issue. I'm doing that anyway. I just want to do that later. I may have actually found an engine out of a mid 80's mustang yesterday. I may have to work on that one.

 

[vdub]

Well I was able to chase the original threads and that worked. However the starter still sounds ugly. It may be the starter bushing is already damaged. I'm not sure. I have started it about 2 dozen times and it isn't getting any worse. I'm going to have to just see how it goes. Since this starter is still working I don't want to drop another $40 on another one since this one is only 2 weeks old.

 

[wildbill23c]

Well mine was starting to make some chattering noise, so I crawled underneath the other day to investigate, well the bottom bolt hole threads are stripped so I'm guessing I will have to tap them to the next size, never ending battle. Somehow it lasted a few months that way so at least if I tap to the next size larger bolt, that will get that fixed for sure I would think. Stupid previous owner's lack of mechanical skills and putting the wrong bolts in mangled the threads on mine.

 

[70roadrunner]

i had the same issue with my 84. finally found the problem. the "nose" on the reman starters is too small, from being cleaned with a blaster. i finally got a good one from napa. i had bought my last starter there, lifetime warranty, and when i exchanged it i got a different brand with only a 3 year warranty. they no longer carry the other brand because of too many returns

 

[PetesPonies]

That's possible and why a shim will work in that situation.

 

[Ryan_D85]

Had the same problem with my 85 put the right bolts in and straitened the motor plate been going about a month now with no problems at all. I think the combo of both made the difference I would deff check the motor plate.

 

[vdub]

Had the same problem with my 85 put the right bolts in and straitened the motor plate been going about a month now with no problems at all. I think the combo of both made the difference I would deff check the motor plate.

my plate is messed up. the hole is oblong from having the smaller bolts in it. I noticed that last weekend when everything was apart.

 

[alwaysFlOoReD]

I just pulled my starter again expecting to see the "bendix" showing signs of contact with the ring gear....nope. It seems that the "bendix" bushing is slightly too large for the starter shaft. It's causing the noise I'm hearing.

Richard

 

[rusty7983]

i ahve had the grinding problem too. What I have found is using a escort 1.9 starter drive. It is 10 tooth compared to 9 tooth on our starters. My starters grinded. The larger drive is like 10 thousands bigger. It has worked on all my trucks. Hope this helps!!

 

[wildbill23c]

Has anyone tapped the threads on the engine to a different size due to the original threads being stripped? If so, what's the trick, there's not enough room to spin the tap.

 

[alwaysFlOoReD]

I have used a 1/4" drive and either 12 point or 8 point socket to drive the tap in close quarters. Be very careful, as it's much easier to break the tap with the extra torque developed by the handle length and the possibility of being slightly off of straight in.
Good luck,

Richard

 

[wildbill23c]

Thanks, may have to try that. Just called local shop for the heck of it and he says $150 to do the job, I was looking at it, and looks like if I use your method, take the starter out first of course, I probably could do it.

Thanks.
Bill

 

[alwaysFlOoReD]

I was just re-thinking my previous post, I might try a 3/8" drive ratchet because of the size. Or maybe try a ratcheting wrench...... Ah, hell I'd just use whatever works in the situation

Richard

 

[wildbill23c]

Haha, well anything would be better than the $150 bill to have a shop spend like a half hour to do this task. The shop tried telling me it would take him an hour just to remove the starter, I just laughed at him, I've taken the starter in and out so many times lately due to the stripped mounting hole problem that I can do it in about 10 minutes now LOL. Anyhow I'll try and get to this sometime this week, I miss having my B2 as my daily driver, far cheaper on fuel than my truck.

I thought about doing a thread repair kit, but from what I've read they aren't exactly a permanent fix, and sometimes will fail, so I figured I may as well just re-tap the hole and use the next size larger bolt.