When necessary for access from underneath the truck, raise and support the vehicle safely using jackstands.
Disconnect the negative battery cable.
On some vehicles access to the wiring may be easier from above. Before raising and supporting the vehicle, check to see if the solenoid wiring is accessible. If so, tag and disconnect it at this time.
On 2.5L engines, remove the brush end mounting bracket from the starter motor.
Tag and disconnect the solenoid wiring.
If the wiring is difficult to access with the starter installed, remove the bolts and partially lower the starter for access to the wiring. If this is done, be careful not to stretch or damage the wiring.
If not done already, raise and support the front of the truck safely using jackstands.
If equipped, loosen the retaining bolts and remove the skid plate.
Remove the retainers and the brackets holding the brake line to the crossmember located just behind the oil pan. Reposition the brake line slightly in order to clear the crossmember.
Remove the crossmember retaining bolts, there are usually 3 on each side, then carefully lower the crossmember and remove it from the vehicle for access.
As applicable and necessary, remove the bracket holding the transmission fluid cooler lines to the flywheel housing, brace rod to the flywheel housing and/or the lower flywheel housing.
Remove the starter-to-engine block bolts. When removing the last bolt, be sure to support the starter to keep it from falling and possibly injuring you.
On some vehicles, even with the crossmember removed clearance for starter removal is tight. As the starter is lowered, it may be necessary to rotate it upside down in order for the end to clear the motor mount, then lower the nose behind the bell housing and rotate it back so the solenoid is on top and the starter may be removed.
Carefully lower the starter and shims (if equipped) from the vehicle.
Position the starter in the vehicle (along with any shims which were removed) and support while threading the starter mounting bolts. Tighten the starter mounting bolts to 30-33 ft. Lbs. (40-45 Nm).
If removed, install the lower flywheel housing.
If equipped, install the transmission cooler line bracket and/or the brace rod to the housing.
Install the crossmember to the frame and secure using the retaining bolts.
Carefully reposition the brake line and secure to the crossmember using the retaining brackets.
If equipped, install and secure the skid plate.
Remove the jackstands and carefully lower the truck.
For the 2.5L engine, install the brush end mounting bracket.
Connect the solenoid wiring as noted during removal.
Connect the negative battery cable.
Tuesday, May 25th, 2010 AT 9:20 PM