Lost nut in starter

[Kenneth Cole]

Of all things. I was replacing the solenoid in my 1991 Humvee starter when the screw holding the solenoid in dropped down into the starter.
I removed the bolts from the end of the starter but tapping on the cover didn't loosen it. So before I go and wreck something I thought I would ask if there is something else I should do.

Ken

 

[fireball]

Try using some of those expanding pencil stick magnets. Try each opening you find

 

[87cr250r]

If it's inside the starter the permanent magnets in the stator will have a hold of it. You're going to need to open it. I don't know your starter specifically but the opposite drive end cover should come off without much fuss as it does on most electric motors. You may want to remove the brushes first so there is no risk of them being damaged.

 

[Mogman]

If it's inside the starter the permanent magnets in the stator will have a hold of it. You're going to need to open it. I don't know your starter specifically but the opposite drive end cover should come off without much fuss as it does on most electric motors. You may want to remove the brushes first so there is no risk of them being damaged.

There are no permanent magnets in a HMMWV starter. and the brushes cannot be removed without removing the end plate first, it is an old school Delco style starter.
I am assuming he is trying to work on the starter while still installed on the engine and has figured out short cuts can lead to problems.

 

[Kenneth Cole]

HI
The STARTER HAS BEEN REMOVED.
kEN

 

[Mogman]

HI
The STARTER HAS BEEN REMOVED.
kEN

Then you should be able to simply roll the starter over and shake the nut out unless you have put the starter in the vertical in which case the nut could have fallen into the field coils and you may have to completely disassemble the starter to get it out.

 

[Kenneth Cole]

Hi
Yes, the nut fell into the starter.
Can I remove the front cover? I removed the bolts from it but wasn't sure if I could just tap it loose.
Ken

 

[TNDRIVER]

Hi
Yes, the nut fell into the starter.
Can I remove the front cover? I removed the bolts from it but wasn't sure if I could just tap it loose.
Ken

If it "fell" in, it should "fall" out. BANG IT ON SOMETHING. Sometimes force works.

 

[Kenneth Cole]

Hi
First you just don't pick up this starter and shake it. It's very heavy. I have tried. The nut has fallen down into the starter and the slot it fell into is very small. Can I remove the end cover on the starter by tapping it off of the housing? I just don't want to do something to wreck it.
Ken

 

[TNDRIVER]

Hi
First you just don't pick up this starter and shake it. It's very heavy. I have tried. The nut has fallen down into the starter and the slot it fell into is very small. Can I remove the end cover on the starter by tapping it off of the housing? I just don't want to do something to wreck it.
Ken

From your description my best guess is that the bolt in question went into the pivot for the Bendix. My first try would be to pick it up at a 45 degree angle with the solenoid on the bottom and "tap" the nose on the ground firmly. I know its heavy. Plan B would be to take the bolts off on the pointy end and remove the housing. At this point you should be able to locate your bolt. If the Bendix is worn also a good time to replace it.

 

[Kenneth Cole]

Morgan
Thanks, would you believe I was able get the dang thing out like you said.
I have two more questions. Is there a trick to tightening up that nut. It's a Ny lock so the shafts rotates when I try to tighten it.
Also can I test the solenoid and where do I apply the voltage.
Sorry for all the questions.
KEN

 

[Mogman]

You really cannot test the solenoid outside of the starter, all you can really do is check the coil for continuity.
That piston the solenoid pulls to what would be the front of the solenoid (as oriented on the vehicle) not only engages the starter drive into the flywheel it pushes a pin that closes the contacts and powers the starter on that end of the solenoid, if you look down inside the solenoid you can see it.
Man that is allot of "solenoid"
If you have it off you should be using a new factory one.

When put together you can connect jumper cables to the the battery connection (large terminal) on the solenoid + and the body of the starter - then run a jumper to the start terminal (small terminal) again +, keep in mind it will likely jump pretty good when energized,
The starter drive should extend into the nose of the starter and it should start to rotate rather briskly.

 

[G744]

I've heard of a loose nut behind the wheel, but never a nut lost in a starter...

 

[Kenneth Cole]

Thanks for all the help.
Ken