More Starter Questions....

[crank]

Hey all. I've been working on this starter problem lately and have come across another problem.
For all of you that haven't been following the saga of crank's starter, this is what I'm doing....

I am taking out the original 97 H1 Wagon starter and replacing it with a aftermarket starter that will fit and run with this engine. I want to fix the original starter and keep it as a spare. Use the aftermarket starter to get me up and running ASAP. The aftermarket starter is a Ultima #03-0447 from O'Reilly Auto. It has worked on other H1's in the past by members in one of the forums. The problem I'm seeing is:

Taking out the old starter is a real bitch! There is a bracket in the front of the starter that I just can't get to laying ion my back. Is there a better way to get to that bracket? Is there a special tool to get to that front bracket? It's very tight in there and I'm on my back.
The aftermarket starter has a different layout for the wires and connections. It looks like I would need to change the terminals on the wires and figure out a way to stretch the wires/cables to fit. Not a direct replacement. Is there a better aftermarket replacement?

Another non related problem, I found a exhaust leak coming out on the passenger side of the H1. It's hard to see but it looks like a clamp is loose or something wrong between the manifold and exhaust pipe. I can feel the blast from it with the hood up. I don't smell anything in the cab though so it's not bad. Is there a better way to get to that? Did I mention it is TIGHT in there?

Any way, if anyone could shed some light on the starter replacement, I would greatly appreciate it.

 

[3Hummers]

The OEM starter is a tight fit. I don't remember doing anything other than wedging my hand in there to get at the nut on top of the starter. Can't remember if I went at it from the top or not but don't think so. The connections on the Ultima are slightly different but the starter is so much smaller that there is plenty of room to make the connections. Is the leak in the manifold, exhaust pipe or at the connection? Could be you need to replace the gasket/exhaust bisquit between the manifold and exhaust pipe. I have had an exhaust manifold develelop a hole. It was rewelded as a temporary fix and then the exhaust manifold was replaced at a later date. Eric Hemminger was selling the aftermarket replacement starters pretty cheap. Not sure if he has anymore or not. They are not watertight like the OEM starters are so I would not do any prolonged watercrossings or dunkings with the Ultima.

 

[crank]

Thanks 3Hummers. The aftermarket starter is noticably smaller than the OEM. Did you have to take the under cage off to pull the OEM starter? I still don't have it out yet. When I couldn't get to the front bracket and noticed one of the connectors would need to be changed, I stopped. I had my neighbnor helping with it. He has about 8 years of diesel engine rebuild for small trucks to 18 wheelers. He has rebuilt his own vehicles in the past. He's even confused on how to get to that bracket from laying on your back. We may need to put it on a lift.
The exhaust leak is hidden pretty well. I know it's somewhere between the manifold and exhaust but hard to see. I'll need to crawl inside I think. It's a big leak. On one of the starts and stops, there was a big puff of white smoke that shot straight up from that area. Just one big puff. The remaining time it was only a little noticeable if you hovered over top of the engine. I don't smell anything in the cab so I think I'm ok for now. I want to get fixed sooner than later.

The OEM starter is a tight fit. I don't remember doing anything other than wedging my hand in there to get at the nut on top of the starter. Can't remember if I went at it from the top or not but don't think so. The connections on the Ultima are slightly different but the starter is so much smaller that there is plenty of room to make the connections. Is the leak in the manifold, exhaust pipe or at the connection? Could be you need to replace the gasket/exhaust bisquit between the manifold and exhaust pipe. I have had an exhaust manifold develelop a hole. It was rewelded as a temporary fix and then the exhaust manifold was replaced at a later date. Eric Hemminger was selling the aftermarket replacement starters pretty cheap. Not sure if he has anymore or not. They are not watertight like the OEM starters are so I would not do any prolonged watercrossings or dunkings with the Ultima.

 

[3Hummers]

Yes you have to remove the shield to get the starter out. I am almost positive that we reached all of the bolts from below the truck. We were on creepers in the shop.

 

[crank]

I'll keep at it then.
TNX

Yes you have to remove the shield to get the starter out. I am almost positive that we reached all of the bolts from below the truck. We were on creepers in the shop.

 

[hummech]

you just remove the nut that holds the starter to the front bracket which you can get to threw the motor mount mounting bracket, the starter bracket stays on the the vehicle. you need to remove the small triangle inspection cover and the two bolts that run threw the starter to the engine block. and the starter will slide out of there.
don't forget to disconnect the battery and the wire off the starter. you will need to modify the small wire that goes to the S terminal on the solenoid.
the exhaust leak is most likely the turbo pipe or the clamps on the right exhaust manafold.