zf5 starter swap
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Mountain Pass
Joined: Dec 2008
Posts: 235
Likes: 1
From: Virginia
zf5 starter swap
Pretty sure my starter is bad. Bats are charged. It was barely turning over for a little while, now it wont turn over at all. I turned the ignition on then took a screwdriver to the posts on the starter solenoid. Nothing, just a bunch of sparks. I guess there are just three bolts for the starter. Got the bottom two off , but this top one is a pain. Can't really get anything to it. Please tell me I don't have to remove the oil pan...
Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
Pretty sure my starter is bad. Bats are charged. It was barely turning over for a little while, now it wont turn over at all. I turned the ignition on then took a screwdriver to the posts on the starter solenoid. Nothing, just a bunch of sparks. I guess there are just three bolts for the starter. Got the bottom two off , but this top one is a pain. Can't really get anything to it. Please tell me I don't have to remove the oil pan...
I've done it more times than I care to count. The only way I've found to do it is use a combination wrench. I can't remember if I used the closed end or the open. Either way it was SLOW going and very very small movements. I wanna say I layed down with my hand and wrench over the frame rail and used the open end. Because of how little you can move it you'll probably have to flip the wrench each time to get a different bite on the bolt.(That is if you can't use the closed end. I had several bolts lately that gave me trouble and I can't remember exactly how I tackled that one but it can be done.)
I also have an extra starter that works too if youre interested...
Post Fiend
Joined: Oct 2003
Posts: 5,903
Likes: 1
From: MICHIGAN
You can reach the top bolt with a combination of wobble extensions and a ratchet from in front in front of the engine cross member. It may help to remove the passenger side tire and work through the wheel well too.......hmmmm, crap maybe I'm thinking of the 5.4/4.6 engine.
Posting Guru
Joined: Mar 2008
Posts: 1,537
Likes: 0
From: Dongola, IL
If you can get the right length of extension you can get it from between the starter and the engine crossmember, but you will have to have just the right combination of extensions. I've changed at least ten starters on these trucks, and yes, that top bolt is a pain!!!! but it is not as bad as the old idi 7.3!!!! don't ask me how I know 
Good Luck!
Good Luck!
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Mountain Pass
Joined: Dec 2008
Posts: 235
Likes: 1
From: Virginia
wow sounds like this has been a pain for a lot of people. It seems like the germans are good at designing stuff to work well, but working on it is a different story. Man, its a hot day to go crawling up under this truck...
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