xf falcon starter motor is this normal?

[djbxr 18]

ok i took the shield of the starter motor to access the drain plug for the block coolant, and noticed the solenoid on the starter motor (black plastic section where the wires connect to on the right hand side in the photo) moves around and can be pulled away from its steel housing about 5mm (disregard the hose clamp in photo). the two nuts where the wires that connect onto the solonoid are tight and there are no other bolts or nuts securing the black part of the solenoid onto the solenoid housing, and there seems to be a paper gasket between the two in the gap as you can just see in the photo. but then i thought maybe its meant to be like this as its probably been like it for the ten years i have had the ute, is this meant to be loose and if so is it what they are talking about in this text from the original workshop manual regarding the starter motor

if its not meant to be like this how do you tighten it up as there are not other bolts/nuts that are holding it on

thanks

 

[dex 2,065]

Back end should be two countersunk screws that locate it

[djbxr 18]

ok thanks so it should be tight then? and not move around?

[dex 2,065]

Disconnect the battery

Remove the cable and disconnect the wire clip

Unbolt the " whole" starter motor

Pull the bugger out , and you will see the countersunk screws ,,

Give them a nip up ,,,

 

Then bung the whole lot back in in reverse order .

 

Surprized you wernt hearing and clacking or anything on fire up ,?

[dex 2,065]

Even if you just feel arround the top of the solenoid , you will get to the " raised " hump ,, thats were the throw out arm that is engaged

By the solenoid punching the arm forward ,

Yhe countersunk screws are either side of the hump

[djbxr 18]

yeah i found the screws just now and they are both done up tight. the solenoid housing (the steel cylindrical bit) is tight and so are the countersunk screws, as i got a small socket wrench with a screw driver attachment on it, so its all tight and the only part that is loose is the black plastic looking cap that the wires fix too

[dex 2,065]

Has " at any time " anyone tapped " with a hammer for instance " ,,at that solenoid to free up a suspected stuck solenoid ,,?

There is one suspect mark there ,,,,

Might have cracked the bakerlight section that the afforementioned screws go in ,,

Ie broke the bakerlight in half

[djbxr 18]

its possible that someone has before me, but i never have as its never caused an issue, although the bakerlight part seems to have a clean straight edge to it  where the gap is between it and the steel part and there seems to be a paper gasket in there so am not sure, might have to take out to have a look at it i guess any tricks to getting it out, have heard one bolt is hard to get to.

 

also with regards to putting it back in i just push it back into the hole and do it up, nothing special?

[dex 2,065]

Yep ,, just bolt it back in .

Nothing real tricky to remove ,,

[bear351c 10,270]

If it's not causing any issues, you could strip it out, put a thick gasket between the gap. Or 2 dabs a of silicone to stop the movement.

I'd say it's been loose for a while, and the countersunk screw "holes" have gotten bigger over time, with the constant vibration.

 

Edit:  Silastic wont stick to oil, must be clean and dry.

[djbxr 18]

thanks, yeah i have just put a hose clamp around it for now, thats holding it pretty tight until i can get around to taking it off and looking at it.

[djbxr 18]

so took the stater motor off turns out the two screws that hold the black cap of the solenoid were missing. the solenoid had a auto electricians sticker on it, but i have had the ute for 10 years so its at least 11 years old since anything was done to the starter motor/solenoid. i am thinking maybe they forgot to put the two screws back in or maybe they have just fallen out.

 

Anyway starter motor started sticking the other day so i took starter motor off and undid the screws at the back of the solenoid that hold the solenoid on, and wiggled the solenoid a bit to get the plunger off the arm but i cant get it back on as there is a fairly stiff spring on the plunger covering up the slot and the arm in the starter motor is a fair way back inside the housing even when i get a piece of wire on it and pull it towards the camera as seen in third photo its still a way back inside the housing. how do i get the plunger onto the arm as it looks like the spring on the plunger needs to be compressed first to expose the slot?

 

I bought a new bosch starter motor to fit it apparently but its much smaller which is fine but because the casting on the starter motor is smaller there is  a gap or hole between the casting of the starter motor and the bell housing as can be seen in the last photo, so i would like to overhaul the old one

 

 

new starter

 

[dex 2,065]

Need to hold the gear that engages the ring gear out . So the arm with the hook that the solenoid is close to the open hole .

Then angle the slot on the solenoid to the top of the hook on the arm ,, just , so you can push the spring back enough to push back enough to slip the slot over the hook on the arm .

Bit of contortion to it ,, but once you've done it ,, it will seem easy .

 

 

Looks like someone has suplied you a replacement from a later model there .

[djbxr 18]

ok thanks for the reply, i shall give it a try.

 

Yeah its a way smaller starter motor, was told it will fit, it bolts on but no good withthe gap to the bell housing for dirt/moisture etc to get into have to overhaul the old one

[djbxr 18]

so i bought the new starter motor from ebay bosch BXF456 and they say it fits but i dont like the fact there is the gap between it and the bell housing allowing dust/dirt/grease etc inside the bell housing, surely this is no good?

[dex 2,065]

Id be checking its engagement as well ,,

But wouldn't want a gap there

[djbxr 18]

Id be checking its engagement as well ,,

But wouldn't want a gap there

yeah i have returned that starter motor as i didnt ever hook it up or tighten the bolts when i saw the gap,so am going to try and rebuild my old one

 

i took mine apart to clean and lube it  and as i was pulling the main internal part with all the wire winding attached to it and this small black plastic part (see photos) came out of inside the body somewhere but it fell out to quick and i didnt see where it came from. i have never taken a start motor apart so i cant tell where it goes and what way around, hoping you can help. photos attached

i am guessing it goes somewhere between the green arrows in the last photo, but i may be wrong as i cant see where it would go, and it came out somewhere around where the white lever is, i thought i may broken off the black part attached to the white lever but i check and it didnt, its got me stumped

[FORD_MAN 1,026]

the small part may be go between the outside of the motor & the solenoid where it meets throw out pivot to fill the gap

[djbxr 18]

got it thanks man

 

does anyone know where best place to get parts for these old larger starter motors, online pref.

 

bushes and brushes/brush holder

[bear351c 10,270]

The numbers give it away......