[Cloud9...68]

I recently received my new starter (from Sunset - only $95 plus refundable $38 core charge, and they're still available at that price, so if you're thinking of replacing yours, you might want to jump on this), and just realized that I forgot to order the bushing that the shaft fits into. I assume this is something I should order and replace along with the starter, right? My car has just under 100,000 miles on it. Thanks.

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[flash]

i've not yet had to replace mine, but i have heard that the new starter comes with a new bushing - did yours not? i'd call sunset - they have made a few mistakes lately - i just received an order of parts for the new car, and they missed a few things, got quantities wrong, etc

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[PorscheDude]

You may need a special tool to remove the old bushing.

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[ds968]

i could not get the old bushing out no matter how many things i tried.. so i gave up and left it there.

it's been working perfectly ok for me

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[Cloud9...68]

Thanks for the quick responses.



Flash - No, my starter did not come with a new bushing, and there's also no menition of it on the invoice.



Yes, I can see how it could be very difficult to remove the old one. I've replaced the clutch pilot bushing on several cars I've owned in the past, and sometimes they plop right out, other times it's a major pain. But I guess unlike a clutch pilot bushing, which is engaged and undegoes wear whenever the car is running, the starter bushing only sees "action" when starting the car, so the more I think about it, if mine doesn't come out realtively easily, I may follow DS968's lead and just leave the old one in there. I'll let everybody know what happens.

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[PorscheDude]

I just replaced my starter. I left the old bushing in.

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[Cloud9...68]

Yeah, I just contacted Sunset, and they told me that a new bushing is supplied with some Porsche starters, but not for the 968. They also told me they don't normally replace the bushing when replacing the starter. My preference would be to replace the bushing, but it sounds like this is more trouble than it's worth, so unless it falls out in my hand, I think I will leave the old one in, and just lube it real well. What I don't want to happen is to struggle for an hour trying to pull it out, possibly damaging it in the process, and ultimately having to leave it in in a damaged state.

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[sasilverbullet]

I replaced my bushing, it came with my starter. Forgot exactly how but I was able to get the thing out - granted my car was on a lift which i'm sure made a big difference on ease...

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[Cloud9...68]

[quote name='sasilverbullet' post='45073' date='Dec 27 2007, 05:38 PM']I replaced my bushing, it came with my starter. Forgot exactly how but I was able to get the thing out - granted my car was on a lift which i'm sure made a big difference on ease...[/quote]

Hmmm... OK, as I said, I'll make an effort to (non-destructively) remove mine, and if I can, I'll order a new one. If not, I'll leave the old one in. What I've done in the past with clutch pilot bushings was soak some newspaper in water, mash it into the bushing, find something whose o.d. is close to the i.d. of the bushing (like a ratchet wrench extension or a hardwood dowel), and pound on it with a hammer. Sometimes, the soaked newspaper is able to squeeze behind the bushing, and the hydraulic pressure is enough to pop the bushing out. It doesn't always work, though.

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[flwbyu]

Do you have the part numbers for the starter and bushing?

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[Cloud9...68]

[quote name='flwbyu' post='45078' date='Dec 27 2007, 08:06 PM']Do you have the part numbers for the starter and bushing?[/quote]

The part number for the starter is 944-604-104-X. I don't have the number for the bushing, but if I end up ordering one, I can let you know.

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[Paul David Anthony]

There must be some special tool to get that bushing out of there because I found it almost impossible to get out with regular tools.

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[PorscheDude]

There is a special tool, I think it was $45.

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[Cloud9...68]

[quote name='smokiemon968' post='45087' date='Dec 28 2007, 10:58 AM']There is a special tool, I think it was $45.[/quote]



Yikes! I think I'll just put some lithium grease on the bushing, and forget about it. That's what two Porsche dealers' parts/service departments I contacted about this recommended.

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[Mark]

From a VW forum

For the 12 volt puller, you can make a reasonable substitution. Use a 7/16" bottoming tap (square end, not tapered), threading the bushing until the tap bottoms. Continue to turn to withdraw the bushing. The square bottom tap will not damage the blind hole and acts as a screw jack to lift the bushing out.



To drive in a replacement, use a 10mm x 50mm bolt with nut. Thread the nut to the depth of the bushing to act as a stop.



Thanks to Taylor Woolard of Knightdale NC, a VW Master Mechanic, for providing that tip

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[Cloud9...68]

This sounds like a good method, but too late, I already replaced the starter. I had forgotten how deep into the opening the bushing is. When I get my aluminum flywheel, which I're sure entails removal of the "bell housing" (or whatever it's called on a car with a rear transaxle), making the bushing much more accessable, I'll go ahead and replace it. The shaft of the old starter was in perfect condition, indicating the bushing must be in good shape as well, so I don't think leaving the old bushing in place for awhile will do any harm.



I'll keep an eye on how much the new starter helps my hot start problem, but I'll probably have to wait till the weather warms up to really be able to check this. At least the new starter should solve the problem of the starter sometimes disengaging after a few cranks, particularly on a hot day.

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[PorscheDude]

To late for me too.



Good info mark.



Hopefully next time someone replaces their starter they will read down this far in the thread.

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