Been having a bit of fun lately.
My neighbor is my physical therapist. He pretty much isn't charging me to treat me for my recent bulging disk/ pinched nerve fun.
He has a junky Nissan Titan that had a bad starter, so I told him we could trade.
Wow, Nissan engineers are a special kind of evil.
Starter is under the intake manifold. What I thought would be a 2-3 hour job at an easy pace has become a months long adventure and patience test.
When I removed the old bolts, the starter wouldn't budge. I first had to break the old starter apart. Then I had to wedge a chisel in there and work both sides. Once it broke free, this is what I saw:
https://photos.smugmug.com/Auto/Bron...7387850-X4.jpg
The internal ring bonded with the outer ring and it wasn't budging. Dissimilar metals suck.
After hitting it with the heat gun for a while, some PB Blaster, and a BFH with the chisel, it came loose, but slipped to the inside of the ring and a piece fell inside the flywheel housing.
I had to use a metal saw to cut the bottom out so it would slip back out the opening.
Once that was done, I rigged up my phone endoscope to a grabber tool and tried to fish the piece out.
https://photos.smugmug.com/Auto/Bron...2529020-X4.jpg
https://photos.smugmug.com/Auto/Bron...2876125-X4.jpg
https://photos.smugmug.com/Auto/Bron...8759773-X4.jpg
Here is the first video of me trying to get it. It is long, and I don't get it right away, but this shows how deep down it was, and what a PITA it was.
https://videos.smugmug.com/Auto/Bron...il/master.m3u8
After a bit, it just fell down into the inspection hole and I found it on the ground.
https://videos.smugmug.com/Auto/Bron...il/master.m3u8
The offender:
https://photos.smugmug.com/Auto/Bron...0889502-X4.jpg
Here is what the piece that was stuck looked like. I had to piece it back together to make sure no other pieces were stuck in there.
https://photos.smugmug.com/Auto/Bron...421355--X4.jpg
I almost just left it in there, since it is AL. It probably would have just been chewed up, but not worth the risk, and I would feel horrible grenading his bell housing.
Here is what it looks like now:
https://photos.smugmug.com/Auto/Bron...4989023-X4.jpg
Got the new gaskets on the intake manifold, and started buttoning it back up:
https://photos.smugmug.com/Auto/Bron...8352011-X3.jpg
Then, I , of course, over torqued one of the bolts and broke it.
Back at it tomorrow to take the manifold back off, plug up the holes, and remove the bolt.
I am oddly at peace with this. It had to happen. It has been one of those projects, and getting practice removing broken bolts is valuable experience.
I plan on drilling a very small pilot hole, hitting the block with the heat gun at max, PB Blaster or Kroil, and then reverse bit. Going for success on the first try.
Wish me luck.