Starter Replacement Disaster
 

Hey all: A co-worker replaced his starter on his 5.7 L Merc (in a Sea Ray) with an aftermarket marine starter. He is good with mechanical installs including using a torque wrench to tighten fasteners. After about 30 hours of run time, GRIND>>>> His fly wheel is now missing teeth in several large spots. You know the first step to replace the flywheel?? Pull the engine....holy time killer. He pulled the old starter out of the box and removed the newly installed starter. The new bolts are 3/16" longer and likely bottoming out before snugging up the starter. Also the housing is 1/16" larger causing even more chance for misalignment. Moral of his story, bite the bullet for Mercrusier parts or double check aftermarket parts to original parts and be careful.

Re: Starter Replacement Disaster
 

Ouch! Thanks for the insight.

Re: Starter Replacement Disaster
 

I replaced my starter last night, what a joy that was!

Re: Starter Replacement Disaster
 

I did it once years ago. i had to use a mirror to put the socket on, lay on my back and reach under the manifold to put the driver on. Pain in the arse for sure and i have no desire to do it again. It might be a bit more helpful though to remove the manifold.

This info from a friend of mine: Get a deep dish 6 point 9/16 socket. get a 2-3 inch 3/8" extension and ratchet. An 'air ratchet' will make the job a bit easier too. Feel ahead of time with your hands and get a feel where they are. One is very tight to the bellhousing cover and it is tight!! (He suggests placing a pad over the engine, laying on it and then reaching down to get at the starter. He also suggested putting a strap around the engine & starter to hold it in place until you had the bolts out & the wires disconnected).

The bolt heads should be approx 1 inch long so you can get that much of the deep dish socket on good and deep. If they are not, when you get them out go get the long headed bolts.

Take your time and be very patient!!

Disconnect the starter wires and attach a wire hanger to support the starter after the bolts are removed.

The bolts go into the block from directly underneath the starter, in other words towards the motor cover top/sky!

Sometimes though, it is simply better to pay a real mechanic to do the job... and avoid all the stress. This might be one of those times.