Bosch Starter Motor - Strip Down & Rebuild, fixing a slow/poor crank without parts

Hard starting when the battery is good, in this video I'll be stripping my Bosch Starter motor, inspecting and finding little wrong with it, but fixing it with basic tools, cleaning solution and fresh grease!
Has this helped? buy me a coffee www.buymeacoffee.com/CrispysP...
0:01 Intro
0:22 opening credits
0:29 I've checked all the the voltages
0:56 Stripping Starter
1:18 Common failure , and further stripping
3:00 Inspecting planetary gears
3::21 cleaning solenoid terminals
4:30 Rebuild start
5:22 Re Assemble planetary gears
5:55 Solenoid end refitting
8:20 How does it align back up?
9:05 Insert windings
10:50 Fitting brushes
11:30 End cap fitting
14:35 Checking by hand
14:50 what parts are available
15:30 does it work
16:30 outro
Read the disclaimer below
I encourage folks working on their own cars, especially anything electrical take great care
Warning : work on your own vehicles at your own risk, I'm not responsible for you messing up. Any doubt seek a professional help or get someone else to do it!
Check your vehicles system before hand and its best practice to disconnect batteries before touching electrics, do you have your radio code, alarm settings, keys out the ignition anything special for your car?
The upcoming videos will either follow the conversion of my '89 Corrado to a finished, running 'super coupe' as VW intended with the highest MPG we can sensibly achieve, using a later Pumpe Duse diesel engine
or
VW related repair or upgrade
follow my instagram @crispys_project
Equipment used - real basic step up all available on Ebay
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Thank you for the support,
I'm a old school VW modifier who would rather build than drive!
#bosch #starter #rebuild

[@jamesunderhill993]

Really helpful. No fuss, no overly distracting music; just calm, clear instructions. Nicely done. Thank you!

[@CrispysProjects]

Thanks very much for watching, very much appreciated 👍 I hope it helps

[@jamesunderhill993]

@@CrispysProjects it certainly helped. Just refitted my restored starter motor to my Saab 95 and the starting problem is completely solved! Thanks again for the great advice.

[@CrispysProjects]

Great to hear it's solved the issue 👍

[@onedegreespot]

@CrispysProjects i went (ok, read was forced to) one step ahead with this complete tear down by having to reseat the pole pieces,the permanent magnets around the rotor. Thats a bit of a pain in the you know where by itself and that pain doubles when you realise that the rotor now turns in reverse and slips the one way sprag clutch. Had to tear it down again, but in the end, it was worth it. Have a video, might post it. Loved your vid, mine is exactly the same unit. Good job!

[@dopiaza2006]

Couple of minor points - It's a good idea the clean the commutator back to clean copper with some emery paper, and clean out the channels between the bars of the commutator with a thin pick. You can even put the armature in a drill to do it. And they're brushes not bushes :) Last one - still sounds a but lazy, maybe think about replacing the brushes anyway as they're not expensive.

[@guyfafard-vv4ro]

Pretty nice rebuilt job my Mate! It sure gives a nice jolt the heart when it goes...

[@damianbutterworth2434]

I use a bit of angle iron with 4 holes drilled into it lining up with the solenoid screws and plunger to press it out in a vice. I used to work in a factory with a press to split them. I used to do about 140 a shift. Bosch 0331 lol.

[@CrispysProjects]

I'm going to say you know what your talking about without a doubt! that sounds like a good way, keeping it all lined up - many thanks to the tip👍

[@tguanciale]

Excellent video, instructions for a starter rebuild!

[@ramongalavis3328]

So easy to fix very nice Job greetings from Venezuela 🤗😜

[@CrispysProjects]

Glad to hear, greetings 👍

[@shaneborg3717]

Me watch, me scared to do hehe! Great work!

[@singbob]

Wish i knew this before i peft my old one out to rot 😂, took it apart and plenty of meat on the brushes and inside looks good but the gear and the clutch thing (cant mind the name) is rusty as now 😢 and my replacement starter just went on the fritz but might try this out on it

[@Flash635]

This has been the only starter strip down video that I've seen that mentions the locating nub on the starter barrel. After I figured it out. After about 2 hours of frustration and tears. In other videos they just slap it together and it all fits. I wish I'd come here first.

[@CrispysProjects]

Thanks for the comment, I'm glad it's helped you out 👍 Hope it's all back together and working just fine I also had the same issue 1st one I done, so worth sharing what goes wrong

[@Flash635]

@@CrispysProjects It's back together and so far only bench tested. 2 of the brushes were getting stuck in the holder and not making a connection. Oh, and you're the only one that said to fit the barrel first then insert the commutator, that helped a lot.

[@monkeynutchewer]

Thanks Crispy for posting this well made and very educational informative video, It has given me a good insight into the problematic Bosch Starter that I'm about to strip, clean and reassemble. Thanks again and I hope you and your channel prospers.

[@CrispysProjects]

Thanks very much, was a fun fix! I hope the starter went well, its fairly straight forward when its apart and its running so much better

[@ghulabkhan762]

Good morning

[@ShakirAuto067]

Good working bro 😊😊

[@jimsworthow531]

you are a good mechanic.

[@CrispysProjects]

Your too kind Jim, thanks for watching 👍

[@MrHouseManager]

Been struggling with hard cranks in the morning for some time now, solved quite a few things along the way, but you are the first to mention ECU needs certain amount of rpm to fire, thanks! This has been driving me nuts! Excellent video!

[@CrispysProjects]

Thanks Max for taking the time to watch and leave a comment, I hope your closer to solving your issue 🤞Yes ECUs need to have to have a point set between the engine running and stalling, couple RPM too low makes a difference

[@MrHouseManager]

@@CrispysProjects All fixed! Starts like a dream now! Exactly the same issue you had, that pesky corroded connection, you gained a lifelong follower my friend 😁

[@MrHouseManager]

Besides, nothing like the feeling of doing it yourself, you should have seen my face of satisfaction, not only of having fixed several issues myself, but of gaining the confidence to keep on doing so on the future, thanks again!

[@CrispysProjects]

Fabulous to hear it's fixed, part of the reason starting the channel, as well as trying to document some of the projects! Keep having a go, it's a brilliant satisfaction when it goes right! 👍

[@peteyscarantics9047]

Yet again excellent video 👍

[@CrispysProjects]

Thanks very much Pete, hope it helps some out 👍👍👍

[@TripperTheDon]

Dope vid! Inspired me to do the same for my e46. Got a good spare from an engine swap.

[@CrispysProjects]

Glad to hear, hope it goes well 👍

[@mudassar34]

Lovely job 👍, uff that vw bleep is annoying

[@CrispysProjects]

Thanks 👍 think they spend years of R&D to perfect the most annoying beep with the hardware available at that time!!

[@stevenharpervw]

Great video . I’ve to take the golf mk1 starter motor apart

[@CrispysProjects]

Little slow moving like the starter, I'm mid way though another rebuild but with new parts you might find more useful, just awaiting parts!

[@stevenharpervw]

@@CrispysProjects my starter just “clicks” so I’m guessing it’s carbon dust build up ?? I hit it a few times and it did work but it does it now nearly every few days so what do you think it is

[@CrispysProjects]

Good chance it's the solenoid either not fully engaging or the level it controls sticking ,try not to tap it too much one of the magnets could come loose Also time's like that being an classic earth's/lives all good Feel free to DM pics

[@mihaidaniel8373]

Does anyone know where I can find the coal for this type of starter. I've open it up because it didn't work anymore and I find out the coals where almost gone.

[@CrispysProjects]

I've found many kits on eBay from both random brands and Bosch advertised, they are normally by type number that's little harder to cross ref, need the Bosch part number from the casing help you I use Autodoc uk website which is great, when buying a number of parts, here's a £3 coupon for new users AC24679507

[@wladimiroff7841]

I`ve just disassembled a similar Bosch starter but the magnets came out all together with the rotor. They doesn`t seem to have been glued, is that normal? I have never seen something like that.

[@CrispysProjects]

Errr, yes your right the magnets should stay in the casing, I have no idea what they're bonded in with, I suspect heat resistant at least. Might of been part of the failure!

[@wladimiroff7841]

@@CrispysProjects I've only fixed my own starters so that's like 5-6 in my whole life and all of them had the magnets staying in case. I also always knew that if I a magnet is not glued anymore I just go get a new starter. It just seemed strange that all if them are moving now and the starter was sometimes working, I thought it's a new design 😂

[@CrispysProjects]

@@wladimiroff7841 glad to hear your keen to fix stuff, no it's not a new design just an old one made cheaper is all I'm finding!! Keep up great work, and thanks for the comments 👍

[@courtn580]

Not sure if you're still monitoring this but great video. Just a question on the one way bearing (clutch) itself - you don't mention getting into it - is it serviceable as well ??

[@CrispysProjects]

Thanks for the comment 👍 Only two options is cleaning or replacement, I believe there's no serviceable parts to it

[@chadburkle1461]

Is it possible to fix it when the starter gear engages but does not spin.

[@CrispysProjects]

Hey, Chad I've not come across many that don't turn by had unless there has been compete failure of something, take it you've gone back partly stripped it to check it out what's stuck and then parts available. Might be an option to find a rebuilt one on an exchange basis (normally cheaper than outright buying) or finding used unit These carry massive current, jamming on could cause massive heat which in is never good near fuel and other plastics Sorry, better stay safe 👍

[@mertinknoetze5603]

I have done exactly the same and now seems that the starter turns other way around and doesn't want to crank the engine. I must say that I've removed the magnets and not sure if I've fitted them same way back...did it happen to anyone else?

[@CrispysProjects]

I've not came across that before, to turn the opposite way would been the earth and lives swapped around which isn't easy. More likely is something isn't right maybe with the throw out arm. strip down again and recheck everything and all the electrical, including the 13mm nuts are clean - good luck and recheck everything many times

[@chadburkle1461]

I can't get it out of the black case

[@CrispysProjects]

C clip from the small cover on the end off? Holds the shaft on the bearing