Studded Starter?? - Ford Powerstroke Diesel Forum
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Old 10-05-2009, 04:01 AM
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Studded Starter??

I don't know if anyone else has had the same problem as me with my starter randomly coming lose, but my father and I came up with a way to fix it. As most mechanics know that a steel bolt going into a aluminum housing is a bad idea, unless it is sleeved well Ford on the 2002 7.3L did this with there starter mount (unsure of the other trucks). Many other cars do the same thing (Steel bolt into an aluminum housing), However when your starter weighs about 5-8lbs this produces the problem. Well instead of tapping it back out and installing new bolts me and my father studded mine. A list of what you will need.

JB WELD 5.99 (any automotive or hardware store)
All Thread 2.99 (1 Ft Section most hardware stores)
Self Locking Nuts 3.99 (Most hardware stores)
Lock washers 2.79 (any automotive/hardware store)
Large Flat washers 1.09 (any automotive/hardware store)

Prepping the old holes, First make sure you clean the old mounting points out really good (Clean of any old aluminum dirt or grease) Alcohol works good or a Heavy duty grease cutter. If you have a problem getting the old striped aluminum out I would suggest a bore brush for a .223 (M16 or AR-15). once the holes are clean make sure they are free of any residue if you use a grease cutter. Now get your studs cut to your desired length insure you have enough room for the starter to slide off of them without interfering with the suspension or frame, but not so short you cant get the nuts on. After you cut them to length put the JB Weld into the mounting holes Fill them up as much as possible and fill every void. Now insert your studs i would suggest inserting the end that you cut into the hole if any of the threads are damaged. Clean any of the excess JB Weld off of the face plate in about an hour go out and test fit the starter make sure the studs line up strait if they have moved any make sure you check it every hour until its stiff enough that it wont move after this it is the waiting game, 6-8 hours later hang your starter tighten the nuts down but not all the way. In 15 hours you can tighten all the way down and start your truck. I would suggest checking the studs and nuts after every start for about 250 miles!! I hope some one might find this helpful!! Good luck and be patient when doing this fix!!
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Old 10-16-2009, 03:03 PM
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Hey, kinda like a rotorhead...

Don't see any reason this wouldn't work.

And I've the disappearing bolt syndrome a few times.
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