Re: starter motor
 

Yes, disconnect the battery!!! I have a "custom" screwdriver with a slightly bent tip I made when I was doing the starter swap, shimming. I went thru 3 "new" starters to find one that worked correctly, two from box places, good one from NAPA. having the clearance of the 4wd axles made swapping and working easy.

Re: starter motor
 

I made a brace & proceeded to fit the motor & used the same shim. I had some problems starting (see timing thread) I then drained the battery so placed it on charge. When I returned & tried again I got a clicking sound as if the battery was flat so I checked the voltage which was 12.7v, I then thought maybe something to do with the switch on Lokar shifter so I checked volts at the starter & got 13v there. So I figured it must be the starter motor, when I had a look the small cog was jambed up. I got some more shimming material twice the thickness & tried again, but it happened again. I put both shims in the thin & thicker one. Again it jambed, so I fitted 2 of the thicker shims & left off my brace incase that had an effect. Again it jambed, I've left it now as it's got dark & temp is down to 3deg C. Not sure if I should shim again or just shim the inside to tilt the motor slightly

Re: starter motor
 

Shimming the inside pad bolt only moves the gear AWAY from the flywheel. Shimming the outside pad bolt only moves the gear TOWARDS the flywheel. If you are using a rebuilt starter the remanf may have machined the pad resulting in to tight of a fit. I went thru three starters and a full weekend before I got a starter that would fit right and the correct shims on mine. It is not rocket science just tedious and attention to how you are methodically moving the starter each time. If you are having to use a lot of shim, replace the starter, there will not be enough contact area to keep the starter from rocking while trying to start.

Re: starter motor
 

Not a remanufactured starter

Re: starter motor
 

It is also possible that the drive return spring is faulty or missing.

Re: starter motor
 

Depending on which flywheel 153 tooth or 168 could be wrong starter

Re: starter motor
 

There is pretty good info on shimming the starter on the bottom of this page.

http://rmcavoy.freeshell.org/starters.html

One problem I have found with rebuilt starters is that the rebuilders like to lay the mounting surface of the end frame on a belt sander to give it a nice fresh machined look that takes metal off the mounting surface.

Re: starter motor
 

I've dropped the starter down & it's resting between the sump & exhaust, when I turn the key the small cog is coming out & returning but not spinning

Re: starter motor
 

Sounds like a bad solenoid, but wait for a couple more to chime in...Jim

Re: starter motor
 

IF you unbolted the starter and let it drop you have lost the ground circuit and it will not work.

Re: starter motor
 

Ah yes of course doh