Removing Starter on a Syncro.....

[amazingdave]

Am I right in thinking that I need to remove the difflock actuator to get my starter off?

Undone the bolts holding the starter in and it seems to be rather neatly obstructed by the difflock....

Tried to undo the small bolts holding the servo body onto its bracket but they are fubarred... Can I replace the bolts with threaded bar if I cut them off and if so what diameter are the bolts?

Ta in advance

Dave

[Pete Nice]

You need to drop the gearbox end of the drive shaft off to get those bolts out.

Spray some wd40 onto the diff lock actuator & clamp some mole grips/vice grips on the bolts. They should come undone.
I think they are M4 bolts. Anything would probably work, even a self tapper. It's only to stop the actuator moving around.

[jed the spread]

Actuator has to come off, i did mine a couple of weeks ago. Prick isnt it

jed

[torchy]

Wow was I lucky. I was all set to do this job as my starter had packed in. Turned our to be the signal wire had come off! Good luck with it.

[Hacksawbob]

pig of a job, turned out mine had a loose main electric cable as the bolt had not been tightened by the engine fitters. Check the obvious before getting in there.
Yes, actuator off I'm afraid
from memory it goes something like
inner CV unbolt
remove (hack off) bolts holding on actuator if they are the same as the fronts etos has them as M4 X 55mm
carefully withdraw actuator a few inches to reveal the roll pin (3mm X 8mm) There may (should) be a 2 part rubber boot covering the punger. drive out roll pin to release plastic body with freind holding other end with mag pickup tool or have a spare handy.
remove the 2 "shackle", bolts and recover packing plate behind.
Check your diff plunger to the gearbox it should freely push in and out spring loaded, now would be a good time to exercise it with some wd 40 to free it up.
starter motor as per 2wd except less space to get to bolts with the tight access of petrol tank.

when refitting the actuator it may help to have a short tube to blow out the actuator with your mouth whilst you refit the roll pin. its a couple of years since i did this so apologies if its not 100%

[Pete Nice]

I fitted a new actuator a few days ago. You won't need to use any air to keep the actuator in postion as it will sit where you put it until you connect the air pipes & run the engine. Take note of which way the air pipes go on too.

There is a circlip to remove before the 2 shackle bolts come off, apart from that it is as above.

[Hacksawbob]

https://club8090.co.uk/wiki/Sy ... rs_removal check the link to BusGoofs at the bottom for Thomas's "its my ball" pictures

[amazingdave]

Thanks for all the advice....

Started the job on Saturday and found straight away that some numpty has buggered the socket headed bolts on the driveshaft, typically they are a mix of allen and star and the last person to refit them tore the hell out of all the star bolts....

Towed the van to work so I can get the welder involved tonight.

Dave

[jed the spread]

Thanks for all the advice....

Started the job on Saturday and found straight away that some numpty has buggered the socket headed bolts on the driveshaft, typically they are a mix of allen and star and the last person to refit them tore the hell out of all the star bolts....

Towed the van to work so I can get the welder involved tonight.

Dave

Knock a ten star bit in. It gets them out.

jed

[axeman]

it's not a 10 star but a 12 star but you will need one about 3inch long and hit it in square and firm with a hammer.

[Pete Nice]

If that doesn't work, a small sharp chisel on the head of it will dig in & turn it. You can then bang the star in or use mole grips.

[syncroandy]

If that doesn't work, a small sharp chisel on the head of it will dig in & turn it. You can then bang the star in or use mole grips.

What he said. Rarely doesn't work for me.