starter rebuild (contacts)

[decke48]

a DIY to rebuild starter contacts. which is the most common problem with subaru and toyota starter (this write up will work with toyota starter as they are the same design)
its off a manual tranny but i dont see any differance from an auto
2.5 or 2.2
tools
hammer
1/4 drive
14mm
12mm
7mm
you can use a vise to hold the starter if you like
NOTE: you will need to remove the contact before you can get replacement ones, so in a nut shell you will need another ride to go pick these up!
and only select places carry these. no autozone, advanced, napa.. will carry these so call around to some non national local autoparts stores if they carry these. some machine shops will have them in stock but will want to match up the old contact to the new

$$$ hundreds dollar starter or $1 for contacts

if your starter doesnt start every time it might be worn out contacts.



1) remove the 3, 7mm bolts
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0324-1.jpg

2) take cover off

3) remove the drive and the spring
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0325-1.jpg
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0326-1.jpg

these are the contacts.. they get worn over the use of the starter
https://sl-i.net/FORUM/images/imported/2008/04/IMGA03271-1.jpg

4)remove the postive sides 12mm nut(if still on), remove the 14mm nut
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0328-1.jpg

5)remove the plastic seal and the o-ring

a tip is to place the components in the order they come out so no mix up and to do one side at a time
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0329-1.jpg

6)remove the contact assemble
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0330-1.jpg

7)remove the paper and plastic insulator
8)take the assembly and face the bolt to point up and the contact is touching the table and tap gentle on the top on the threads so the contact and bolt seperate
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0331-1.jpg

9)place the new contact on the bolt facing away from the threads but the plastic on then the paper to look like this(my contacts are that bad)
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0332-1.jpg

10) place the assembly back in to the starter and put on the o-ring than the plastic seal, thread on the 14mm nut, tighten the nut till the contact seats onto the bolt, tighten down. place the 12mm(doesnt need to be tightened)
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0333-1.jpg
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0335-1.jpg

time for the other side (be careful with this contact or youll need a new starter)
11) remove the rubber cover on the negitive side, remove the 12mm nut, pull of the solnoid wire
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0336-1.jpg
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0338-1.jpg

12) remove the 14mm nut, plastic seal, and o-ring

13) remove the contact assembly(be careful this side had a copper wire attached to the assembly (bad pic) do not break the wire be gentle or you will need a new starter
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0339-1.jpg
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0341-1.jpg

14)remove the plastic insulator and the bolt from the contact(this side the bolt and contact are not pressed on)

15) assembly the contact assembly with the new contact.. it goes contact, wire, plastic insulator)
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0342-1.jpg

16) place assembly in starter, put o-ring on, than plastic seal, thread on 14mm, tighten, place solnoid wire on, thread on 12mm, tighten place rubber cover back on.
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0343-1.jpg
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0344-1.jpg

that sides done.

17) take the starter drive and lightly sand (220 or a fine paper) the outer rim
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0348-1.jpg

18) place the drive back into the starter (make sure the spring is on it)

19) place cover back on making sure the gasket is on it, thread in the 3, 7mm bolt and tighten

woot now your done.. almost just need to put back into the car.

if you like you can bench test the starter with a battery jumper.
the ground goes on the starter case(not the negitive side bolt!)
touch the positve to the postive side bolt only for a second(dont burn out the starter) just to make sure the starter spins and the drive pushes out the teeth.(basicly this)
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0345-1.jpg

heres a pic of engaged and disengaged
disengaged
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0346-1.jpg
engaged
https://sl-i.net/FORUM/images/imported/2008/04/IMGA0347-1.jpg

hope this might help someone save some cash

[Airgne]

good stuff to know.

[bangedlegacywagon97]

Fyi, I bought the starter contacts from my local subaru dealer. They were like 10 bucks for the set.

[TGX4776]

WOOHOO! Bookmarked

[decke48]

Fyi, I bought the starter contacts from my local subaru dealer. They were like 10 bucks for the set.
but did it come with the driver?
i bought just the contact from a local autoshop named Cowan one contact was 9 cents the other was 23 cents. i didnt get the driver though reused the old one

[ouch1011]

We offer this as an option to installing a new starter at my shop. Its super easy once the starter is out (kind of tricky on some Toyotas, esp. the V8s). And much cheaper than a new starter.

[Mr Evolution]

Wow, gonna head to Subaru and get this done for my '91 Legacy!!!

[Zedhead]

FWIW, This pix suggests that the contacts are +Positive, -Negative

When in reality, they are BOTH +
Here's another resource for the rebuild parts. The Ad says dodge, but they use the same Nipondenso starter as Subaru. Contact the seller, and tell them Your application.

http://cgi.ebay.com/ebaymotors/ws/eBayI ... MEWNX%3AIT (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=190459703006&viewitem=&sspagename=STRK%3AMEWNX%3AIT)

https://sl-i.net/FORUM/images/imported/2008/04/IMGA03271-1.jpg

[Mr Evolution]

Thanks gonna dive into this rebuild next week.

Please don't ever take those pics down!!!

[nikolaus.conrad]

Did this today and it took 30 minutes, Awesome write up!!

[1-3-2-4]

My starter does not do anything when I touch the bolt and the clamp is on the starter I just replaced the contacts.

nevermind I got it.. had to twist the jump pack clamp to get the bolt and 12v solenoid.

[StatGSR]

huh, this is funny, i rebuilt the contacts in my Honda Starter last fall, had to get my replacement contacts from the toyota dealer as well since honda doesn't offer a rebuild kit either.

[1-3-2-4]

Funny I went to the dealer closest to me and they looked at me funny.. they said we have a starter..

in the end I went to Dan perkins (AKA) Subarupartsforyou.com and I picked up the contacts for $11 I did not get a new plunger anyways I just put the stater back in and it's good now!

[Heli0s]

Does anyone have any advice on removing the starter from a 1st gen Outback? It's pretty well tucked in there and I am hesitant to remove parts to create more room, as I am pretty new to the whole car maintenance thing. I see one bolt that is accessible from above (which is VERY tight) and another that appears only to be accessible from under the car (haven't tried to loosen that one.) Are these the only 2 holding the starter in place? Sorry for the newb questions, and my apologies for resurrect a year old thread. Any advice would be helpful :)

[1-3-2-4]

Uhmmm I can't remember off hand but yes you have a bolt on the top and the underside of it, you also have to disconnect the stater wire from the battery to the starter.

For me I did it in a parking space without jacking the car up as soon as I got home (burned my hands) but I had the starter out in like 8 min tops.

I think the starter bolts are like 14mm but don't hold me on that, the wire that goes to the battery I think is a 10 or 12 mm nut.

[Heli0s]

For me I did it in a parking space without jacking the car up as soon as I got home (burned my hands) but I had the starter out in like 8 min tops.

Impressive! I ended up having to remove the big black thing in the rear of the engine compartment (what is it?) in order to get a breaker bar in there (the bolts were tightened to ~45 ft lb!) Took maybe an hour and a half for the whole rebuild, which didn't seem to bad for a complete noob. Thanks for the awesome guide decke!

[1-3-2-4]

Maybe mine was not as hard as I had removed it two years ago? Subarus are so easy to work on.