HOW-TO: Replace Starter Bushing

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Fri, 25 Jun 2010 17:12:52 +0100

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. - danb

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Tue, 23 Mar 2010 07:47:50 +0100

;D 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' ;D - Snowwag

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Thu, 11 Mar 2010 19:25:39 +0100

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! - Tom

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Mon, 22 Feb 2010 06:27:43 +0100

Thanks! Super solution. could not have been slicker. :) - Bob

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Fri, 11 Dec 2009 17:01:06 +0100

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 - Maggie B

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Thu, 12 Nov 2009 15:02:05 +0100

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. - Gord McFarling

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Wed, 07 Oct 2009 14:48:11 +0100

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. - tina

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Tue, 23 Jun 2009 21:13:53 +0100

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

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Sat, 23 May 2009 21:29:51 +0100

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! - David in Seattle

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Fri, 01 May 2009 14:41:55 +0100

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. - Josh

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Sun, 22 Mar 2009 15:45:52 +0100

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

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Sun, 01 Feb 2009 12:48:59 +0100

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 [i] 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[/i] - Brittany

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Thu, 18 Dec 2008 12:56:59 +0100

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 - David Dixon

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Mon, 20 Oct 2008 10:51:09 +0100

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 - Nick

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Wed, 16 Jan 2008 09:35:58 +0100

good job thank you - bill krupey