Hi,

I'm finally getting around to setting up my T1 cranky kit, and can't for the life of me figure out how to remove the Subaru pinion (and I didn't what to start going gungho and possibly damage something).

Does anyone know or have tips on removing (and refitting) the pinion on the Subaru starter? It seems to be held on by a circlip that is captive by a ring and doesn't seems to allow enough space for circlip pliers etc.

Any tips or pointers much appreciated.

Thanks
Peter

Hey mate.

It has been a long time since I did mine so this might not quite be accurate. But I think I held the starter in a vice and then held the shaft extended out (can't remember how sorry) Then I think I just used some sharp screwdrivers/seal picks to get the clip out. I remember it being a real pain though. Sorry this is all I have to offer.


Smiley

As above, it is not an easy job but can be done, If I remember I disassembled the starter and put a shaft up inside the pinion to keep the gear extended to gain access.

Thanks guys. You've pretty much confirmed there's no secret overlooked method to easily remove it. So I guess I'll pick up (!) some seal picks and try and get at it.

Starter Motor Disassembly

Start by unscrewing the long bolts (8mm head) which hold the back of the motor to the front housing. Take care at this stage as nothing is holding the motor assembly onto the rest of the starter. Turn it over and unscrew the two bolts (8mm head)which are either side of the pinion. Now gently tap the front housing away from the top motor casting. While removing this please ensure no parts are lost.


With the front housing off you should now be left with the gear from the motor, an idler gear with a roller type bearing in the centre (careful not to loose these 5 rollers in plastic cage) and finally a pinion shaft assembly (sometimes this will need to be gently tapped from the front housing) carefully lift this off the solenoid push rod and spring as there is a small ball bearing which is usually found inside the hole in the pinion assembly.

With a Phillips head screwdriver (or blunt tool) held in a vice, take the pinion shaft assembly and place this over the screwdriver. Find a socket or appropriate tool to push the retaining ring down towards the pinion while pushing down on the bearing and gear. Tap the retaining ring down to expose a circlip. Pull this off the shaft using snap ring pliers and a small screw driver or seal pick and remove pinion (noticing the spring under/inside pinion).

Subaru Starter Motor Assembly

Lightly grease the spline with some grease and slide the spring then the supplied pinion back onto the spline. Put the retaining ring on first, then the circlip.With the aid of a vice and two steel plates, pull the splined shaft to the extended position and place the two steel plates either side of this shaft under the pinion. Position the circlip in the groove and then gently tap the shaft down to pop the retaining ring over the circlip.

Place the ball bearing back into the hole in the pinion shaft assembly and fit the spring behind it to stop it falling out. Lightly grease the gears and bearings. Assembly is the reverse of the disassembly. Place the pinion shaft assembly over the solenoid pushrod and align the centre idler gear with inner rollers and cage onto the shaft of the front housing and push together with the motor housing. If it wont go on, Don’t force it !! It should slide together easily before the bolts are needed.

Paul, those instructions are fantastic. Thanks for taking the time to reply.

It can be tricky, as you ideally need 4 hands,
One to hold downwards pressure on the shaft assembly to allow access to the snap ring,
One to grip the snap ring pliers and spread the snap ring,
Another hand to get a small screw driver or pick to pry the snap ring up and off the shaft
And finally one to grab the snap ring before it shoots across your workshop into the black hole of nothingness where all the important parts and tools roll or bounce and are found years later

been having trouble with emails bouncing so unfortunately couldn't respond to it prior

For any one else these have been going strong for almost 10 years now....so if you need them.....

I have both 2L (091) and beetle/kombi cranky kits in stock.

Also doing a run of shorten subaru sumps at the moment.

These are the original Custom Offroad design pretty much the shortest on the market with stock oil capacity as well as ej invert manifolds as well.

0410 571 010

Paul,

Your instructions worked a treat. The actual circlip wasn't much of a problem to my surprise (although luckily the circlip gods smiled on me and it got flung somewhere I saw it land...phew). What was the trickiest was holding everything together (i.e. the actual motor) whilst putting it back together whilst aligning teeth and stopping things falling out.

Nice piece of kit so can't wait to use it.

Cheers
Peter