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Old 05-14-2021, 04:32 PM   #1
Eucoila
 
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Default D21 starter bolt removal

Hello folks!

Thanks for adding me to the forum. I have enjoyed rebuilding a 1994 4x4 d21 2,4l extended cab with my son....his first vehicle! And a manual to boot! We live in MD and have to deal with a lot of rust, but the truck was cheap so we like to work on it ourselves. And for the past year, itís has run very well.

That being said, this is totally a hobby and I appreciate anyoneís help that know more about these vehicles than me!

So, I have appears to be a bad starter; ignition switch is fine, everything powers On, starter relay clicks away....but zero crank. I mean zero. I checked all the grounds, and all test perfectly with my meter; wires are all clean and no corrosion; fusible links check out as good, as well as their connections. So I wanted to check the wiring on the back of the starter, just to make sure connections were good, etc., I went to remove said starter...and the top bolt appears to be rounded! OMG! Bottom one came out fine, but that top one is just in there. So far Iíve used PB blaster and a reverse socket (I think thatís what theyre called...but the latter really isnít seated correctly so itís not getting a good bite.

Does anyone have a suggestion on how to get this bolt out, once itís damaged like this? Seeing that it bolts into the tranny, I really donít want to make it worse!

Matt
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Old 05-14-2021, 05:44 PM   #2
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Welcome to the forum.
The click, click, click is quite often due to the starter relay on the passenger fender, near the fusible links. It looks like a double wide relay compared to the rest. I'm sure a quick search in the electrical forum will bring up threads on that topic.


The biggest problem you face with the starter bolt is access. Take out the inner fender splash shield and jack up the front. You may be able to access it from the side.

The bottom on mine was a bolt. The top was a stud with a nut. Yours may differ. But what I remember using was a 15mm ratcheting box end wrench. It was the only thing that would get all the way on.


Any room for Vice-Grips?

Maybe a nut splitter. (If it's a nut) Yes, that's a thing you can buy. Growing up in New Jersey, I had my share of rusted nuts that had to be split to remove them.


You might also try a chisel and a hammer to break it loose by putting the chisel against one of the flats so that hitting it will force it in a counter-clockwise direction.


PB Blaster is weak sauce compared to Kroil, which you may be able to find at Napa.
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Old 05-14-2021, 07:16 PM   #3
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Quote:
Originally Posted by Reserector View Post
Welcome to the forum.

<snip>

PB Blaster is weak sauce compared to Kroil, which you may be able to find at Napa.
I totally agree with both!

Welcome and get a can of Aero-Kroil. Both are a benefit!
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Originally Posted by Deerhurst
What he is saying is the aerodynamics of a D21 is a brick in the wind.
Probably at least as bad as a Jeep so worse than a cow.
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Old 05-14-2021, 08:46 PM   #4
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Excellent, excellent! Indeed I was heading towards the cold-chisel route. A stud, huh? Wow, that'd be cool....I'll take a close look, as I thought mine was a bolt.

Aero-Kroil...sounds serious. What about heating the bolt, or is that too dangerous in that location?

thanks again!
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Old 05-15-2021, 01:04 AM   #5
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Sadly it isn't a stud.
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Old 05-15-2021, 01:15 AM   #6
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Not that this would help you with a rounded head but one trick I used to get mine loose was putting a wire/string over the end of the wrench that I could then loop down toward the ground and get my foot through and put some weight on it.
If you can get some vice grips on it as tight as possible, think outside the box on getting some leverage doing something like that.
Always get the vice grips as tight as possible the first try before they slip off and round it even worse.
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Old 05-15-2021, 01:21 AM   #7
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You can also come up in front of the starter with a 14mm socket and a 6" extension. Get it seated on the bolt first then use a long flex head ratchet to crack it loose. It's kind of a pain to get to. As counterintuitive as it may sound sometimes you can get lucky hammering a 12 point socket onto a rounded bolt if there's enough left for it to bite into.

Last edited by SBJ; 05-15-2021 at 01:27 AM.
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Old 05-16-2021, 12:46 PM   #8
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Use these. I have had good luck with them.

https://www.harborfreight.com/search...bolt%20remover

Or something like

https://www.amazon.com/adjustable-so...ustable+socket

Last edited by kellybig; 05-16-2021 at 12:53 PM.
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Old 05-18-2021, 06:24 PM   #9
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Heating the bolt won't help. You'd need to heat the part that it is threaded into.


Jarring it can be beneficial. The shock can sometimes help break it loose.
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Old 05-18-2021, 08:47 PM   #10
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if you havent busted your knuckles yet... have you tried checking the relay??
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