Also swap the positions of the studs if their lengths are the same. Due to the direction of the current flow and hence the arcing, 1 will burn much worse than the other.

Baltic Blue wrote:

PF-GF57

GraemeS wrote:

Also swap the positions of the studs if their lengths are the same. Due to the direction of the current flow and hence the arcing, 1 will burn much worse than the other.

Sorry Graeme/Mike ,
I didn’t see the request for stud measurements until later, after I had rebuilt it, but like Mike I think the one under the main copper bar feed is shorter. The nut size is 17 mm.

PS. A note of caution.
The wire connector to the coil broke away from the crimp as I pulled it apart, so I had to do a repair by soldering a bit of the earth wire from a scrap piece of 1.5mm twin & cable I had lying around.
Mike. G reg 2.5VM Vogue Portofino red 1991- 1999
V reg 2.5td P38 Rioja red 1999- 2006
53 reg td6 Vogue Oslo blue 2006- 2015
11 reg 4.4 TdV8 Vogue SE. Baltic blue 2015- date.
https://www.fullfatrr.com/forum/topic56162...tty+affair

I think it would be safe enough to bank on just cleaning-up the bolt heads and plate when the starter fails rather than needing to have new bolts on hand, although if I had new bolts then I'd certainly fit them.

GraemeS wrote:

Could you ascertain and advise the stud's shank dia and length please? eg standard M8 x 30mm. The head dia would also be useful.

Here you go Graeme:

Brilliant photos Mike 👍
One contact in mine was worn completely smooth, but as can be seen in my picture , polished up OK with no ridges, but I am not sure if that would make any difference?
I have been looking for any product that would reduce contact burn, silicone grease or similar, but not found anything.
Mike. G reg 2.5VM Vogue Portofino red 1991- 1999
V reg 2.5td P38 Rioja red 1999- 2006
53 reg td6 Vogue Oslo blue 2006- 2015
11 reg 4.4 TdV8 Vogue SE. Baltic blue 2015- date.
https://www.fullfatrr.com/forum/topic56162...tty+affair

Great stuff guys!

Mike have you refitted the old one then?

. Cheers, Greg
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
2011 Vogue SE 4.4 with lots of toys in Stornaway

Thanks Mike for the pictures showing the dimensions. My son-in-law works for a company that produces starter motors amongst other components so I'll see if he can help.

gonna_go_double_r wrote:

Great stuff guys!

Mike have you refitted the old one then?

No, I had to keep the car on the road (otherwise i'd have to drive the wife''s Focus.......oh, the indignity ) so fitted the new one instead.

But, that's part of the reason for the thread......if anyone finds themselves with a non-starting starter, and are not desperate to get the car back on the road, they can (for a bit of time and effort) save themselves £260+

Mike

GraemeS wrote:

Thanks Mike for the pictures showing the dimensions. My son-in-law works for a company that produces starter motors amongst other components so I'll see if he can help.