VinceWaldon.com

This HOW-TO covers removing and replacing the starter bushing in the A1/A2/A3 VW.

 This is an important proceedure any time the starter is removed, replaced, or if the bushing makes noise.  In particular, most new Bosch starters come complete with a new bushing and a warning label that states the warrenty is void if the bushing is not replaced.

DISCLAIMER:

• Use these instructions at your own risk
• Read them through from beginning to end before starting
• This is how I do things… it is not necessarily the right way nor the best way !
• Using equipment,tools, and supplies incorrectly could result in serious injury to you or your property or even death

Please note:  You can click on any thumbnail below to see a larger version of the image.  After viewing the large image, you can click anywhere outside the white image border to return to your spot in the text.

Parts needed:

       1     new starter bushing  

1. general purpose grease (I use Canadian Tire's finest)
2. brake drum cleaner
3. compressed air

Tools needed:

1. 11mm tap (7/16" should work as well)
2. 1/4" socket and ratchet to drive the tap
3. 7/16" bolt and nut... used as a drift
4. hammer

Step 1: Disassembly

Start the 11mm tap in the bushing:

Use the 1/4" socket to to rotate the tap:

As you rotate the tap it will eventually bottom out and then drive out the bushing:

  Keep turning until you have completely removed the bushing:

Step 2   Reassembly:

Clean the hole with brake drum cleaner and compressed air:

Coat the new bushing with grease and place it in the hole:

Place the bolt/nut combination in the bushing:

Tap gently with a hammer:

This will completely seat the new bushing:

Comments (15)

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written by danb, June 25, 2010

Nice,,, It did not go exactly as planned as I discovered there was not a bushing present. Not good since I am the only person that has worked on this car in the last 37 years. Still an elegant solution to a difficult task.

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written by Snowwag, March 23, 2010

worked like a charm with a 7/16th tap while under the bus. Nice DIY and thanks. PS if your going to replace your starter. Spend a few more bucks and get new Bosch or factory rebuild. Will save you a ton of time in the long run... Keep on Bussin'

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written by Tom, March 11, 2010

Vince, Sir you are a genius. Picked the new starter this morning, found a note about the bushing. Called back to Auto Zone to see if they had "the special" tool, course not, the guy actually told me not to bother changing it. I felt different so I did a google and came across this. Worked like a charm, thanks!

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written by Bob, February 22, 2010

Thanks! Super solution. could not have been slicker.

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written by Maggie B, December 11, 2009

Amazing! I live on the island of Oahu in Hawaii and nobody had a bushing remover tool! This was so simple and easy to do. Now, I just have to re-order the bushing because like David, I bent mine trying to get it in! Any ideas where to order new ones?

Hi Maggie... thanks for your comments. This should be a very cheap part at a VW dealer, but assuming one of those is a couple of islands over the WorldPac mailorder guys carry 'em cheap as well.

Vince

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written by Gord McFarling, November 12, 2009

A little trick to save upo some cleaning time. Cut a plastic cup and insert it base first under the bushing, and tape it in place. The swarf will fall into it, and when you are done it saves a lot of extra cleaning.

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written by tina, October 07, 2009

Awesome tutorial. Bushing came out with ease. Just don't forget to clean the metal shavings out. First time working on my bus by myself and I feel like a pro. On the 78 a 10mm by 50mm bolt works best.

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written by Rally Eddie, June 23, 2009

Great write up. The procedure worked flawlessly. I used a 7/16 tap since they are easier to find around town. Cheers.



Hi Eddie... glad to hear it worked for you... I've never personally tried the 7/16 tap but the math said it should work... glad to hear it does!!
Vince

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written by David in Seattle, May 23, 2009

Thanks for the insightful tutorial.

I was able to get the old bushing out of my '74 Ghia, but I can't get the new one in. I ruined the bushing that came with my new starter, so I've had to order a replacement (actually 3, just in case.) How easy/difficult should it be to get the bushing even an 1/8" into the hole, so I can tap it in with the nut/bolt combination? Mine didn't seem to want to go in at all.

BTW, I'm trying to install in a vehicle that's still assembled, so I'm under the car, contorting myself to get into a position to reinsert the bushing. Thanks in advance for any help!

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written by Josh, May 01, 2009

This same basic procedure will also work when rebuilding a diesel van starter, which houses two bearings in pressfit holes at each end of the shaft. However, these holes go completely through their housings, providing no base against which a tap will bottom out and then provide a screw-like function to remove the copper bushing. Carefully striking the tap with a suitable hammer will drive the bushings out of their holes. Inspect the old bushing surfaces, and drive the old bushing out from the direction that appears most suitable. Then install it from that same direction.

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written by Stefan, March 22, 2009

Thanks for the photos and description. Made the job a breeze.

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written by Brittany, February 01, 2009

Thank you for the pictures and descriptions. I have just installed a new bushing and am having troubles getting the starter in. When I put the bushing in, it went in easily at first, but I could not get the last fraction of an inch in. With a couple good wacks, it eventually appeared pretty flush, but I'm worried that it bent the bushing because now I can't reinstall the starter. How easy is it to put the starter in? Does it need a whack with the hammer or will that destroy the starter?

Any insights would be helpful.

Thanks,
Brittany



Hi Brittany:

The starter should slide in fairly easily. When it doesn't what I normally find is that I've over-done it with the grease on the new bushing... this forms a bit of a plug and because the grease is thick and the bearing clearances are small the extra grease keeps the starter shaft from going in all the way.

Have a look and see if there's a wad of grease at the bottom of your new starter bushing... if so, a q-tip will dig it out and I bet your starter will slide on home. ;-)

Let us know what you discover!!!


Vince

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written by David Dixon, December 18, 2008

By far the simplest way!! Love Your stuff/lay men can follow everything You say, Not! New to VWs 35 yrs. Just ran across these different,
instructions==+++++ Good Stuff. David

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written by Nick, October 20, 2008

How easy is it to do this with the engine in the car?



Hi Nick... no problem at all... I had the tranny out to make the pictures easier but the steps are exactly the same, once you remove the starter.

Vince

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written by bill krupey, January 16, 2008

good job thank you

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