How to re & re the starter

[tdiflyer]

Just got rid of the post-start "buzz" on my third TDI. Removing the battery and doing it from the top is the only way to go - R&R completed in 60 minutes flat! There's no need to disassemble the starter if you just want to silence that noise. You'll find the output shaft can rattle a little bit in its bushing. That's just enough slop for it to vibrate as the starter spins down, which is what causes the buzz. To lube, you only need to pull the shaft out as you rotate clockwise (from the gear end), spread some grease on the smooth surface of the shaft and then rotate it counter-clockwise a couple of times to spread the lube around. Wipe off any excess grease so it doesn't get on the clutch, then reinstall the starter. This is all I've done to mine each time, and it always solved the problem. The fix doesn't last forever, you have to do it every year or so.

 

[gbclassic]

Hi
thanks for all this info. I could not have done it without you guys

My bolts were 16mm rather than 18 though

As I pulled the cable guide of of the way 2 wires can off from somewhere (that's when I discovered they had been "repaired" before--need to sort those when the starter is fixed)

EDIT
I didn't listen when I was told to put the short bolt back so the mounting sprang out of line even with the jack. I made bolts with a long long taper and used them like a podger to line up the holes. Then when I had it aligned put the short bolt back, removed the top alingment tool and replaced it with the standard bolt but I had improved the point on it to get the bracket to line up
Once Again THANKS
George

 

[H8GAS]

Thanks Wingnut! I just did this today and so far the squeal is gone. I hope it lasts! I also took the advise of blowing out the opening in the bell housing, a lot of dust came out.

 

[gmenounos]

Thanks for another great how-to! Last weekend I replaced the starter on my 99.5 Golf with a refurb to fix the "brief grind after starting" problem. Not only did that take care of the noise but now it cranks (and starts!) noticeably faster than before.

Greg

 

[shaneb75]

Thank you Sir

Thanks Wingnut! I have had this problem intermittently for a while and it is becoming more frequent. I am going to give this process a shot to see if it works for me...

 

[jcilforever]

Any one have experience with an 04 BEW starter? Is it the same?

Any one have experience with an 04 BEW starter? Is it the same?

 

[canadianvballer]

Just did this last night. Car starts up quicker and quieter.

I have a frostheater and defender skidplate, I removed the battery and tray, and eventually had to remove the skidplate so I could get to the bottom bolt, but didn't have to jack the car up. I thought that form where I live (Alberta, Canada ie corrosion city) that my ground strap would be ready to fall apart when I took the starter out but it seemed to be in good shape. I used wheel bearing grease around the planetary and the mainshaft, starts like a wet dream now.

I'll post back if it gives me trouble again in the future.

 

[AntonLargiader]

Did this last week, from the top. Pulled the battery and tray, had no problem with the lower bolt. I removed the solenoid and the motor from the nose casting, then thrust the pinion forward and cleaned the exposed shaft. Did this several times to make sure it was clean, then applied a light film of moly paste and reassembled. Wiped off the solenoid and solenoid cavity and gave a very light film of grease there also. Put a touch of new grease into the planetary gears, but they looked pretty good already.

I agree; the real problem is that there is too much radial clearance between the pinion and the nose casting bushing. I didn't measure, but maybe 1/2 millimeter? Couldn't fix that, but we haven't had the noise a single time since then so I'm coloring it 'done' for now. Will probably look into a rebuild kit so I can replace the nose bushing next time.

 

[prsa01]

wire harness on top of starter / top bolt access

Since I posted this I saw the posts by vatechTDI & cooter09, I'll try their suggestions. Thanks

I'm stuck at what seems to be an easy step for everyone else. Not sure if I'm just a knot-head or if the 99.5 is a little different (probably a knot-head). When you say "pry off" the wiring on top of the starter what exactly do you do? Mine has a number of wires in a plastic sleeve thing. I've tried prying under that with a screwdriver but don't want to ruin the wires. I'll add some pics to better show what I am talking about but any guidance before then is appreciated.

Thanks

 

[AntonLargiader]

The wires are on a cable holder that slides onto a metal tab, which is in turn held on by the starter mounting bolt. So, the front bolt holds the AC or PS hose, and the rear bolt holds the tab for this cable holder. I slid the cable holder off the tab to the right (nothing seemed to be locking it onto the tab).

Is this what you were referring to?

 

[prsa01]

AntonLargiader,

Yes, that is the part I was talking about. Thanks for the help!!

 

[punkvideo81]

Thanks for this how-to. I just replaced the starter in my 2001 Jetta automatic with a new one from German Auto Parts. I had the same confusion with the wire shroud removal. Ended up removing the battery tray to get a better look and got it out fine. Had to run to the parts shop for an 18mm socket, it was the *only* socket I didn't have. They didn't have them individually, so I bought a set of deep sockets. Opened it up & it only had odd numbered sockets, so I had 17mm and 19mm (you couldn't tell from the package that this was the case). Went back and got the right one from another shop in town. Ugh.

 

[keldar]

Anyone have trouble getting the top stud out? Mine wont come out all the
way. The bottom one came out ok.

For the top one, It appears the threads on the end of it
are bigger then the hole in the engine block. Sounds like perhaps
the nut was supposed to come off, not the whole stud.

its on a 2001 beetle tdi.

 

[Shawnz]

Anyone have trouble getting the top stud out? Mine wont come out all the
way. The bottom one came out ok.

For the top one, It appears the threads on the end of it
are bigger then the hole in the engine block. Sounds like perhaps
the nut was supposed to come off, not the whole stud.

its on a 2001 beetle tdi.

I did mine last night - it'll come out eventually - just keep unscrewing it. It's like mine have to un-thread twice.

It was a complete PITA but it came out eventually.

Mine fought em the whole way. Top bolt explained above, the shroud was a pain till I figured out I can slide the plastic part off the metal bracket. The bottom bolt the nut holding the AC bracket had fused itself so turning the nut was just moving the A/C lines around. Once I got that loose it went pretty smooth.

 

[jcilforever]

can anyone help? I got it taken apart and put back together I am just having issues getting the cover back on am 1/2 or less to tall for the srews to get a hold

 

[duwem]

Just got doing it, under 2 hours for sure. Did it from the top down, why roll on your back and have to mess with the skid plate. Battery is out in 10 minutes. And I mean come on, disconnect the cables, unless you want the risk of an arch welder under the hood!!!

I will say I got it apart on the work bench and the lubrication instructions are pretty vague. Did a combination of chain lube on the bendex style shaft and a little wheel bearing grease on the planetary gears.

Engine was still warm when I fired it back up, but it seemed to spin a little faster and didint hang up. Tomorrow mornings 30F start will tell for sure if it did anything.

 

[sc00byd00311]

Any one have experience with an 04 BEW starter? Is it the same?

Just did mine. Even the inside of my starter looked the same as in Wingnut's picture. My problem was that damn plastic wiring doodad over the top 13 mm nut. Battery and battery box=nothing happening; no battery or battery box = done in 3 hours at a leisurely pace.

Edit**
God bless the edit function.

 

[jcilforever]

can anyone help? I got it taken apart and put back together I am just having issues getting the cover back on am 1/2 or less to tall for the srews to get a hold

Well I used a high temp grease on mine ( Royal Purple 01312 NLGI No. 2 High Performance Multi-Purpose Synthetic Ultra Performance Grease )

It used to make a screeching noise and now is silent used it on all gear sufaces, bought on amazon

 

[duwem]

Well, sound is back, that lasted about a week. Either I didnt lube the right stuff/ not enough lube, or after 250,000 miles the starter is just worn out.

 

[coolvdub]

Just did this yesterday. I had a screach happening at the end of the start cycle. I pulled the starter and dis-assmbled it like Wingnut did. But I pulled the plastic gear carrier for the planetary gears out, but still connected to expose the solenoid pivot fork area. I used plenty of brakeclean to flush out the area and lubed the gear and contact areas with white lithium grease.

I also pulled the small panetary gears and the sun gear out and got them completely clean and re lubed with the lithium grease as well. I also lubed both ends of the stator shaft (I believe that's what it's called) also. The grease that was in there was all rather hard or gummy and seemd to not be doing it's job any longer.

Went out this morning and started the Jetta up in the 20 degree morning air we are having and the car started much easier and the starter sounded great. Well worth a couple hours time, we will now see how long this lasts. Much better than spending a couple hundred on a rebuilt starter

 

[ymz]

I also lubed both ends of the stator shaft (I believe that's what it's called)

That would be the Rotor... the Stator remains Stationary...

Cheers,

Yuri

 

[jcilforever]

Royal Purple 01312 NLGI No. 2 High Performance Multi-Purpose Synthetic Ultra Performance Grease is the way to go has high heat application of course CL2 antiseeze might work too.

 

[Eric 1207]

EDITED TO SAY THAT AFTER REREADING THIS THREAD MOST OF MY QUESTIONS HAVE BEEN ANSWERED SO I WILL DIG INTO THE JOB AND ADDRESS ISSUES AS I ENCOUNTER THEM. HOWEVER DOES ANYONE HAVE A DEFINITIVE ANSWER ON #3; WHICH GREASE WHERE? THANKS. I WILL LEAVE THIS POST AS IS IN CASE IT MAY HELP SOMEONE ELSE.

Last week, only one day after purchasing my 2003 Jetta Wagon the starter began making a vibrating, whirring or high pitched buzzing noise when the key was released after the engine started. Is this a worn bendix gear bearing? I suppose it could be any bearing that is in the rotor itself. For now though, I am surmising the bendix gear is no-load freewheeling on the worn bushing of its bearing after disengaging from the flywheel and spooling down. It takes up a resonating vibration to cause this not too loud whirring noise. It only lasts a few seconds after key release. In this thread I have seen a few descriptions of symptoms similar to this but I'm not exactly sure its the same. Also the battery is new and I have had no problems starting in zero degree weather, I just have the transient whirring noise after key release.

My questions are:

1. Can this bendix gear/bushing be replaced like on the 1960s Fords of my youth or do I need to buy a whole new starter? I saw one post that eluded that there are no serviceable replacement parts for the starter. Another said you need to replace the bushing in the bell housing, which might be my problem.

2. If I can buy a replacement bendix gear/bearing/bushing does anyone have any tips or procedure for going about removing and replacing it. I have gone through this thread and can see what might need to be done but would love advice from someone whos been there. Also should I get it from a dealer or is there a better aftermarket supplier?

3. Related question: There are several different lubes people have used in this thread, from wheel bearing grease to super duper fancy name with lots of spec numbers and decimals. Is any old bearing grease ok and will it suffice for all the friction surfaces/bearings/gears in the starter or should I be more selective in what specific grease goes where? Maybe I should ask a dealer.

4. Some have disassembled the starter to get to friction surfaces and gears inside, others have not and just lubed up what they could reach. Should I go to the trouble of taking the starter apart for a full relube or should I just stick with my symptom and grease (or replace) the bendix gear bearing/bushing? (maybe I have to disassemble it to replace the bendix anyway)

5. If I disassemble completely I guess I will look at the brushes and see if they are ok, any advice on how long they should be to still be serviceable? Some one sanded the commutator, what grit should be used and is a few blasts of compressed air good enough to get the grit outta there and away from the bearing surfaces?

One post indicated a similar noise/symptom so he removed the starter and lubed up the bearing surfaces and it worked great …..for about a week then it came back. Another says his has to be done once a year. I think they may have the same issue I have. A bearing somewhere, (I think bendix) is worn out and needs replacing. The lube will fix it very briefly. I wonder if the seller did this to mine to conceal the problem. He was a used car dealer who had just bought it a few days before from a CL private seller. Neither the TDI Trusted Mechanic nor I detected it in our check out. My tough luck I guess.


Thank you for any advice

 

[djmiller]

I just purchased a lifetime warrantied starter from NAPA, when the noise starts, I call them to get another starter. Doesn't take that long to replace.

 

[ssjimbo]

Just Finished Replacing Mine

I replaced mine with a Bosch reman from IDParts. Car had been off for a couple weeks. Before that I had to jump it, even from an overnight sitting. The last straw was getting stuck at work on a not too cold day. The new (to me) starter is amazing. Car starts like a gasser now . The warrantee on the Bosch is really good as well.

My only issue was that I did some damage to the shroud/wiring holder over the starter when trying to get it out. I broke a piece (maybe 1/2) off. When I put it all back together, I put back what was left and I think it will be ok. I decided against the rebuild since my car has almost 220k. I really didn't want to pull it and replace it twice.

 

[fruitcakesa]

I just purchased a lifetime warrantied starter from NAPA, when the noise starts, I call them to get another starter. Doesn't take that long to replace.

I did the same from our local Bond Auto and went through 3 of them before some flywheel teeth gave up the ghost. Replaced the TC/FW and after that, no more starter problems.

 

[Steve74]

Starter Help...Thanks

I just wanted to say thanks for the great write up! Mine would not start yesterday morning and after a bunch of research I located the burnt off braided line off the solenoid. I used the copper trick to replace the burnt off wire and it works awesome
So happy to have found this site to help me since I am new to owning a VW(bought it almost 2 weeks ago)

 

[Enix82]

Just wanted to say, all these years later, your tutorial still works!!! I just changed my starter by this gospel of a guide. Since it was my first time, I took the battery box out - and I'm glad I did. I didn't have any trouble until I got to the starter bolts. I was afraid they were seized because I could not break them loose! However, much to my dismay, I was trying to tackle the entire job using a 3/8 ratchet on the deep 18mm sockets. I went to the store and upgraded to the 1/2 and popped those babies loose.

The top bolt was kinda a PITA. The double threaded was a pain since it had to be turned right at the AC metal pipe, which was bound and determined to stay in the way.

But all is well, and yep, I feel like a manly man.

 

[jcilforever]

Royal Purple 01312 NLGI No. 2 High Performance Multi-Purpose Synthetic Ultra Performance Grease is the way to go has high heat application of course CL2 antiseeze might work too.

Been at least 6 months starter used to make squeeling noise every time VW tech said they just make that noise. Used the Royal purple from amazon as it is a high heat grease on all gears and shats inside, still like butter

 

[sc00byd00311]

Been at least 6 months starter used to make squeeling noise every time VW tech said they just make that noise. Used the Royal purple from amazon as it is a high heat grease on all gears and shats inside, still like butter

Thanks for the report back! I think i'm gonna try that grease next time!