My starter motor started getting stuck back in November, it was only once every so often and i ignored it until now, since xmas it has been getting worse rapidly and recently i have had to "tap" it with a bar of metal and a small hammer nearly every time i want to go somewhere. enough of the back story, i put in a new one this morning.

first of all, ignore EVERYTHING the workshop manual tells you on page 1316 and 1317, with obvious exceptions like disconnect the battery etc.

there is NO access from the top what-so-ever, it's a lie, even if you move the power steering resevoir and air intake pipe out the way, it changes nothing, the wiring loom blocks all access. same below the car, no need to unbolt the exchaust, or the rebreather pipe, no need to undo anything underneath, it is 100% possible to remove and refit the starter motor on a TD100 without disturbing any other pieces.
this is not to say it is easy, far from it, access is difficult and i had to stop and rest my hand from cramp more than once, but it is possible.

i suppose all i want to say is that what the workshop manual tells you to do , is of no real help at all, just get straight underneath and have at it with your 13mm sockets. done in 2 hours, could have been 1 if i hadn't followed the workshop guide.

hope this helps somebody.

good job.. working well again..??

the older Tipo/tempra it was on the FRONT of engine.. so acres of space.. but filled up with oil ( from leaky gaskets), and road crud,

never actually replaced one.. used to strip them , and once clean worked well again..,

Charlie

oh it starts beautifully Charlie, like new, half the time it fires up on the first revolution. a whole weight of stress has been lifted from my shoulders, i was worried every time i went out somewhere that i would have to call on passers by for a push. luckily since i moved house recently, i now live in a hilly region and so the odd occasion it wouldn't start at all, i was saved by gravity.
i will have a play with the old one, see if i can recondition it, if so, it will stay in my box of bits as a spare, or it may end up as a contender against an old chainsaw motor as the means of propulsion for my boy's go-cart project.

just in case anyone is curious, i opened up the old starter tonight, it seems the brushes are *slightly* worn.
i think a set of carbon brushes and a good clean is all it needs.
Charlie, do you have any suggestions as to how i remove the crud from the stator magnets, i would take a wire brush to it and then blast off the magnetised bits with compressed air, but my compressor is dead, due to (take a guess) worn brushes!

I have 2 x old jam jars + LIDS with a toothbrush + petrol in ,

1, for the cruddy jobs..

and another for "flush / rinse effect",

my older motors were always full of an oily paste ( oil , carbon, road grime)

several rinses - and an old t-shirt - ..did the job,
with a toothbrush.. you shouldn't scratch any grooves in to cause a short / arc..,

Charlie