How do you replace a starter motor on a Rodeo or Passport without removing exhaust parts?

Answer 1

On some 4WD models, the starter motor is caged in by part of the exhaust system. If the motor is truly caged and removing the exhaust is not a reasonable option, then there is an alternative--partially disassemble the starter motor and its replacement into 3 pieces each, shuttle the pieces out and into the "cage" and reassemble. There are some things to watch out for. For related information see http://forum.planetisuzoo.com/viewtopic.php?t=9161&highlight=starter This is from experience with a 1998 Isuzu Rodeo V6 3.2L 4WD: Tools needed: * 14mm socket. Deep socket or a socket with an extender. * 9mm socket with a narrow body such as for 1/4" drives * 8mm socket with narrow body such as for 1/4" drive. * 12mm, 13mm sockets or wrenches for electrical components * Bailout items: Philips screwdriver, bailing wire * Remove the 2 bolts and 2 long screws from the starter housing. This may require a combination of 8mm and 9mm sockets. Partially disassemble the new unit into three pieces. Use care to not separate other subcomponents: # Point the Pinon gear downward and separate the gear housing from the solenoid housing. This orientation will ensure that you don't spill out greased gears or the spring bearing. # Carefully separate the Solenoid housing from the motor housing. First remove the bolt that electrically connects the two parts. Next, carefully separate the two housing parts by pushing the protruding motor gear past the solenoid housing. The push action is intended to keep the motor shaft snug against its housing during the separation process. If the shaft comes too far out (1/2 inch on one model), the brushes will collapse inward and you'll have to resort to Plan B to reseat the shaft within the spring-loaded brushes. Plan B may required removing 2 screws from the end of the motor housing to get access to the (4) spring-loaded brushes. Press the shaft sideways against one set of brushes, then work the shaft onto the other brushes one at a time. Having disassembled, the new unit, you'll be prepared to disassemble the old unit within the cage. Disclaimer: read your manual for safety etc # Be sure the starter problem was correctly diagnosed and that this alternate approach is still preferred over removing the exhaust. These two extreme methods are for those cases when the opening appears to only allow something roughtly the size of a soda can to pass through. # Be sure the front of the car is safely raised. # Be sure the negative cable is disconnected from the battery. # Remove the 2 mounting bolts. # Remove the start terminal lead. This model clicked in/out of place. # Remove the positive cable from the starter. # Remove the 4 bolts that hold the housing together. # Point the pinon gear down if possible, then separate it from the rest of the housing. Remove this piece from the "cage" # Unbolt the electrical connection between the Solenoid portion and the motor portion. # Separate the solenoid housing from the starter motor housing by pushing the prutruding gear back past the solenoid housing. Ideally the motor shaft will stay with the motor housing, but if it separates, remove the shaft as a bonus part. Remove the two parts of the housing one at a time. If the motor shaft comes apart and it is needed for core charge or other reason, reassemble the shaft as in Plan B mentioned for the new unit. Assemble the new starter inside the "cage" # Insert the new solenoid portion into the "cage". Orient it so that it can receive the motor gear when the motor portion is inserted # Insert the motor portion into the cage, mating it snugly with the solenoid portion. The electrical wiring from the motor should be near its mating electrical post on the solenoid. Also see the potential alternative ordering mentioned below. # Consider temporarily looping a wire snugly around these two piece to ensure the motor shaft remains seated until the third piece finally bolts in. # Orient the assembly in the cage so that it will receive the gear housing, and anticipate that the drain portion will eventually be pointing downward when the unit is fully assembled. # Hold the Solenoid assembly high in the cage while inserting the gearbox portion of the starter into the housing. Keep the pinon gear pointing somewhat downward so that the spring bearing etc stays in place. # Position the spring on the solenoids plunger and into the corresponding hole in the gearbox, then assemble the full starter, removing the temporary wiring, and bolting the housing together with all 4 bolts. # An alternative ordering might be to insert the solenoid, then the gearbox underneath it. These two parts can actually bolted together after you insert the spring. This would be a nice way to quickly minimize the number of unsecured parts. It's not clear if there would be sufficient room to insert the motor portion. # See if there are any parts that need to be transferred from the old starter to the new starter such as the guides that fit in the mounting holes between the car body and the starters body. # Reconnect the wiring between motor and solenoid, the start terminal lead, and the positive cable. # Remount the assembled starter in the cage, using any necessary guides in the mounting holes. # Reconnect the battery.