How To Starter Replacement

LibertyFever

Full Access Member
Joined
Aug 17, 2007
Messages
933
Reaction score
0
Location
New Brunswick, Canada
I've begun to notice that lately my Libby doesn't easily start. The starter may be failing. Reading through the service manuals it appears that I have to partially dismantle the exhaust manifold, is this true?
 

Bulli

Full Access Member
Joined
Jul 22, 2011
Messages
54
Reaction score
0
Location
South Africa
On the 2.4 and 3.7 i know you have to remove a piece of the down pipe, 2 clamps. Diesels not to sure.
 

LibertyFever

Full Access Member
Joined
Aug 17, 2007
Messages
933
Reaction score
0
Location
New Brunswick, Canada
On the 2.4 and 3.7 i know you have to remove a piece of the down pipe, 2 clamps. Diesels not to sure.

Doh!

Sorry, I should have mentioned that my Libby is 3.7 L V6 gas powered.

I haven't actually poked my head under the hood yet (it's been raining for the past three days) but from studying the service manual I seem to understand where the starter is and why the manifold must be partially dismantled.
 

LibertyFever

Full Access Member
Joined
Aug 17, 2007
Messages
933
Reaction score
0
Location
New Brunswick, Canada
Okay an update for everybody.

The starter problem has begun to get worse quickly. It's not likely going to last the week and I have plans for an anual trail run this upcoming weekend.

I've shopped around for a new starter and the cost of rebuilding the old one.

#1. I don't have the time to remove my old one and have it rebuilt
#2. if I buy an aftermarket there's a chance I'll get a model that won't fit so I'm going with a Mopar/Jeep brand new replacement (approx. $150)
#3. I've found where the starter is on the engine and understand now why the manifold has to be disconnected. It's a real tight spot.
#4. but the bolts require a short 10mm socket that I don't happen to have and they're in such a tight place that I can't budge them, not even the manifold nut
#5. I have buddies of mine who are more than willing to help me replace the starter but I'm pressed for time & I really don't want to impose on them with what will likely be a frustrating job

So I'm biting the bullet and orderings replacement starter from Mopar & having a local garage replace it for me. Maybe I'll have the old one rebuilt for the next time.
 

JeepCoMJ

Full Access Member
Joined
Nov 29, 2010
Messages
629
Reaction score
8
Location
SE WI
I just did a starter on an 02 3.7l limited today, without removing the exhaust manifolds at all.

Tools needed;

3/8 drive 15mm 6 point deep and shallow sockets
3/8 drive 6" extension
3/8 drive air ratchet
3/8 drive impact
1/4 drive 13mm deep well socket, 6 point
1/4 drive 8mm deep well socket
1/4 drive 6" extension (preferably swivel type extension)
1/4 drive fine tooth ratchet
10mm ratchet wrench
small flat head or right angle pick
12" pry bar
small hammer (1/2lb ball pin worked just dandy)

I started by disconnecting the battery, then removing the driveshaft bolts on both ends, then adjusting it and sliding it up and out of the way.

After that, I took off the transmission to engine bellhousing brace. This is what the 3/8" extension and both 15mm sockets and the both air guns (ratchet and impact) are for.

After that, I removed the heat shield from the starter, via the 3 10mm bolts (this is what the ratchet wrench is for. the Gear Wrench Flex-beams work nice for this)

Then I unclipped the ignition engage wire from the starter with the right angle pick, and unbolted the plug adapter from the starter using the 1/4" ratchet, extension with swivel, and 8mm socket.

Then use the 13mm deep 1/4" drive socket and ratchet without extension to unbolt the positive cable

Following this, I unbolted the starter from the block. Once it was free, I was able to turn it 180 degrees so the solenoid was facing between the bell housing and the front pinion yoke.

Slid it down, wiggled, realigned, slid it down further, where it bound just a tiny bit on the upper driver catalytic converter. At this point, I was able to slide the pry bar between the bell housing and starter, and coax it the last 1/4" to watch it drop to the floor.


straight into the scrap pile, grab new starter, orient it appropriately, slide it in until it binds, and use a 1/2lb hammer to tap it in until it is just past binding, then realign and install opposite of removal process.


I ended up deciding to go this route for two reasons.
1.) my hands don't fit in by the exhaust manifolds to disconnect the upper 02 sensors
2.) even in the best situation, a spring-loaded exhaust clamp, and a flange clamp, once they've started rusting, are NOT going to come out easily.



Worked great for me, everything is ready to go.
 

WyldWolf777

Active Member
Joined
Jan 3, 2022
Messages
125
Reaction score
46
Location
Weslaco TX
I just did a starter on an 02 3.7l limited today, without removing the exhaust manifolds at all.

Tools needed;

3/8 drive 15mm 6 point deep and shallow sockets
3/8 drive 6" extension
3/8 drive air ratchet
3/8 drive impact
1/4 drive 13mm deep well socket, 6 point
1/4 drive 8mm deep well socket
1/4 drive 6" extension (preferably swivel type extension)
1/4 drive fine tooth ratchet
10mm ratchet wrench
small flat head or right angle pick
12" pry bar
small hammer (1/2lb ball pin worked just dandy)

I started by disconnecting the battery, then removing the driveshaft bolts on both ends, then adjusting it and sliding it up and out of the way.

After that, I took off the transmission to engine bellhousing brace. This is what the 3/8" extension and both 15mm sockets and the both air guns (ratchet and impact) are for.

After that, I removed the heat shield from the starter, via the 3 10mm bolts (this is what the ratchet wrench is for. the Gear Wrench Flex-beams work nice for this)

Then I unclipped the ignition engage wire from the starter with the right angle pick, and unbolted the plug adapter from the starter using the 1/4" ratchet, extension with swivel, and 8mm socket.

Then use the 13mm deep 1/4" drive socket and ratchet without extension to unbolt the positive cable

Following this, I unbolted the starter from the block. Once it was free, I was able to turn it 180 degrees so the solenoid was facing between the bell housing and the front pinion yoke.

Slid it down, wiggled, realigned, slid it down further, where it bound just a tiny bit on the upper driver catalytic converter. At this point, I was able to slide the pry bar between the bell housing and starter, and coax it the last 1/4" to watch it drop to the floor.


straight into the scrap pile, grab new starter, orient it appropriately, slide it in until it binds, and use a 1/2lb hammer to tap it in until it is just past binding, then realign and install opposite of removal process.


I ended up deciding to go this route for two reasons.
1.) my hands don't fit in by the exhaust manifolds to disconnect the upper 02 sensors
2.) even in the best situation, a spring-loaded exhaust clamp, and a ****** clamp, once they've started rusting, are NOT going to come out easily.



Worked great for me, everything is ready to go.
This is excellent with great detail. Thanks
 
  • Like
Reactions: klc

Ramboflorence

New Member
Joined
Mar 24, 2022
Messages
12
Reaction score
0
Location
sherwood park ab
I've begun to notice that lately my Libby doesn't easily start. The starter may be failing. Reading through the service manuals it appears that I have to partially dismantle the exhaust manifold, is this true?
I found it easier to take the starter apart to get it past the exhaust
 

jeepop

Full Access Member
Joined
Mar 16, 2017
Messages
124
Reaction score
50
Location
Middle Tenneesee
I found it easier to remove the propeller shaft on my 06 4X4 before removing the starter.

Also, I got better bite on the prop shaft bolts with a 5/16th vs a 8 mm socket.
 

Deb'nKJ

Active Member
Joined
Jun 3, 2022
Messages
111
Reaction score
74
Location
somewhere between London & Zunny Deb'n (England)
I've just read this with some trepidation, because, as far as I can make out, I need to remove the starter to undo the manifold/downpipe clamp - because the exhaust needs to be removed to get the front driveshaft out. Vicious circle/Catch 22/can of worms/one way trip to the scrapper - you decide.
 

Latest posts

Members online

Top