T4 starter motor not engaging.

[Racemag]

The DOKA has been running fine and was driven 90km from home and parked up. In the morning it started fine, but 4 hours later it did not start. The noise was strange, as though the pinion was not aligned with the ring gear. Bumping the engine to alter the flywheel position did not help much - a slightly different noise was all. A short push-start got the engine running immediately and we came home. Park in the driveway and the same starting issue means the car will be sitting for a while. Battery is 12 months old and sits with 12.6 volts - plenty of power. Not an earth issue as starter runs just fine, not a switch issue. So I assume I am up for a new $350 starter motor?

[LogicprObe]

Check the bolts holding it in first.
When I had a T4, the bolts came loose but I got to it too late as it cracked the starter motor housing and I had to get a new one anyway.
I hope that's all it is for you.........just a tighten up.

[Racemag]

Check the bolts holding it in first.
When I had a T4, the bolts came loose but I got to it too late as it cracked the starter motor housing and I had to get a new one anyway.
I hope that's all it is for you.........just a tighten up.

Well done! Exactly this - two bolts loose and third alloy mount point cracked through. Thought of welding the lug, but new starter motor to be ordered.

[Racemag]

sadly further inspection shows that threads stripped on two bolts - a bigger repair needed.

[Sunny43.5]

How about redrilling and re tapping new thread slightly bigger if there is room , or maybe drilling right through and using nuts and bolts ?

[Racemag]

Helicoils have been ordered.

[Sunny43.5]

Good idea let us know how it goes .

[Racemag]

should be fine, though the top blind hole has limited access.

[LogicprObe]

Bugger.
Sometimes what seems a simple repair turns into a saga!

[Racemag]

It is what I'm worried about. Cutting thread lying on my back on the driveway is not ideal

[Racemag]

Back running. I went and got two threadsert inserts as I thought the blind hole on the bellhousing was going to be a problem - the bigger problem was the lack of allow to drill out for the threadsert. In short I thought there would not have been enough around the insert - so helicoils it was. I had to snap the drill bit in half and resharpen to get access - the drill and bit was too long to fit between the bellhousing and the chassis rail. So I got the helicoils in and then cross-threaded one and stripped it! Fortunately this was the bottom open hole and a long bolt and nut solved the problem. Starter motor back in and vroooom! it started. Starts with a bit more pep, but then a $440 starter motor should be an improvement.

[Sunny43.5]

Getting at bolts can be the pits sometimes drilling them even worse , glad to hear you had a successful result . T4,s are tough beasts .

[jets]

. Starter motor back in and vroooom! it started. Starts with a bit more pep.

I am pleased to hear you are going again.

[LogicprObe]

Good work!

[Racemag]

Thanks for all the positive feedback. I thought I'd use it for a week before claiming success and all is good. I'll check the bolt tightness every six months or so. Now all I need is a glass rear window for the DOKA and all will be moving in the right direction.