Studded Starter?? - Ford Powerstroke Diesel Forum
LinkBack Thread Tools Display Modes
post #1 of 2 Old 10-05-2009, 04:01 AM Thread Starter
Serving Our Country!
Join Date: Feb 2009
Posts: 557
Thanks: 0
Thanked 0 Times in 0 Posts
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
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!!

1964 Riviera (stock wouldn't have it NE other way)
1983 Toyota pickup (Diesel Conversion In Future) SOLD and Just got it back!!!
2002 F-250 W/ 4inch Turbo back exhaust and K&N air filter SOLD
2005 EX stock 6.0PSD

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
PWRSTROKETHIS is offline  
Sponsored Links
post #2 of 2 Old 10-16-2009, 03:03 PM
Coal Rolling = Posing

Join Date: Nov 2007
Location: Cumberland Furnace, TN
Posts: 9,872
Thanks: 0
Thanked 1 Time in 1 Post
Mentioned: 0 Post(s)
Quoted: 0 Post(s)
Feedback Score: 0 reviews
Hey, kinda like a rotorhead...

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

And I've the disappearing bolt syndrome a few times.
chvyrkr is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Ford Powerstroke Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome