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Foot Starter Alignment

Discussion in 'Early CJ5 and CJ6 Tech' started by Don X, May 22, 2021.

  1. May 22, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    I'm having trouble with my starter foot plunger being out of alignment and being too far from the starter lever. When the plunger is completely compressed it's more than an inch short of the lever and it isn't lining up to the top of the lever.

    Background. It's a 24 volt M38A1. I took the starter off and removed the solenoid to clean it up and check it out. Nothing seems amiss.

    The plunger has been off for several years as I pulled the tub to have the hat channels on the bottom of the tub replaced. I have small puck spacers on the body mounts. Without the spacers the tub would sit a little lower which would put it even more out of alignment.

    About 10 years ago I had to move the plunger mounting holes a little after a rough trail ride that caused a slight alignment problem but nothing as severe as it is now.

    If I raise the tub a little more it might help the angle of the plunger but the distance between the plunger and starter lever will still be a problem.

    Any thoughts?

    PXL_20210522_171543612.jpg
     
  2. May 22, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    More background. I've also swapped the T90 with a T98A. That included a different bell housing. I think it was the same dimensions but even if it was different the starter to flywheel dimensions wouldn't have changed. Yes?
     
  3. May 23, 2021
    garage gnome

    garage gnome ECJ5 welder

    Western MA
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    Swap to a key start starter. :D

    What bell housing did you use when you put the T98A in? I thought the 4cyl T98s used the stock bell housing with an adapter? Thats how the one I had was. Are your engine mounts and transmission mounts all in good shape?
     
  4. May 23, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    Bell housing was another F134 just not military. Had to use the adapter.

    The mounts are in good condiion but that's a good thought. I'll check the cross member height.
     
  5. May 23, 2021
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    I'd suspect that before anything else. But that misalignment is not minor.
     
  6. May 23, 2021
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    cut and weld the bar . shop fabrication
     
  7. May 23, 2021
    garage gnome

    garage gnome ECJ5 welder

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    The military bell housing and civvy one are identical as far as the starter location.
     
  8. May 23, 2021
    PeteL

    PeteL If it wasn't for physics, and law enforcement... 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Sure it can be 'fixed.' But I'd always prefer to know the cause.
     
  9. May 24, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    I vaguely remember using shims when I put the cross member on. Can't remember why or how thick. If the rear of the tranny can be raised that might be enough to line the lever up properly. It will definitely affect my tranny cover. Not sure how much of the distance between the plunger and lever will be corrected. Won't be back out there until the weekend.
     
  10. May 24, 2021
    elawson

    elawson New Member

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    My CJ5 with the factory T98 has the regular bell housing with an adapter between the T98 and the bell housing. The CJ5 frame had a 2nd set of crossmember holes that are drilled farther back than "the normal T90 ones". Also, there were (probably) 1/2 inch thick blocks of hardwood between the frame and the crossmember.
     
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  11. May 24, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    I think, or at least hope, that is what is changing the starter alignment.
     
  12. May 24, 2021
    elawson

    elawson New Member

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    I just measured the wood block thickness...3/4 inch. These blocks are on the driver side and passenger side of the transmission crossmember and LOWER the crossmember below the frame.
     
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  13. May 28, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    I had it shimmed 3/4” as shown in the first picture. If I drop it to about 2” total (2nd picture) I end up with what's in the 3rd picture. Still not enough and more of a drop than I'm comfortable with. I haven't checked yet what it does to the drive shaft angle.

    Any thoughts?

    PXL_20210528_154415611.jpg

    PXL_20210528_193352170.NIGHT.jpg

    PXL_20210528_193248621.NIGHT.jpg
     
  14. May 29, 2021
    Don X

    Don X The Prodigal Moderator Staff Member 2023 Sponsor

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    I'm running out of ideas as to what is causing the problem. I'm starting to understand what motivates the Bubba living inside us. Options I see are:

    1. Extending the foot plunger. This seems really awkward.
    2. Having the starter lever modified so it's closer to the plunger. I dont weld so I'm not sure how to go about this.
    3. Change the solenoid so it is wired to the ignition switch. I'm far from interested in this. I like the foot starter. It's a low tech anti-theft system.
     
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