Dismiss Notice



Register Today It's free! This box will disappear once registered!

Upper starter mounting bolt missing 93 Explorer

Discussion in 'Stock 1991 - 1994 Explorers' started by Dubious_Downfall, October 2, 2018.

^^Searches ExplorerForum.com^^
  1. Dubious_Downfall

    Dubious_Downfall New Member

    Joined:
    July 6, 2018
    Messages:
    44
    Likes Received:
    3
    Trophy Points:
    8
    City, State:
    Bonney Lake, WA
    Year, Model & Trim Level:
    1993 Ford Explorer Sport
    Did my front brakes yesterday. It should have been a moment of relief, but after driving it maybe 50 feet, turning it off, and trying to start it again, I could hear the starter spinning, but no contact with the engine. I initially assumed my starter was bad. After getting a push start, then driving out to Pick-n-Pull, pulling a starter and bolts from an automatic first gen explorer, and paying for it, I crawled under my truck in the parking lot, grabbed my ratchet, and promptly realized nothing was holding my starter in but the cramped space.

    Now my problem. Luckily, I grabbed bolts from the donor truck. Unluckily, only the lower bolt fit. For some reason, the threads on the top bolt seem ever-so-slightly too large to fit the existing mounting hole. I tried in vain for 15 minutes to get that bolt to thread into that hole. The only reason I can think that the bolts would be different is that my truck is a manual, and the donor is an automatic. Otherwise, there may be a year difference. I don't know.

    To lay it out: I have a 1993 Ford Explorer Sport 4x4 Manual. The production date is October 1992.

    I need thread size and bolt length. I'd just go pull a bolt from a manual to try it, but literally every Explorer in their yard is an automatic. Any help is appreciated. I can't stand hearing the starter grind and fail to start my truck properly any longer.
     
  2. Support EF

    Join the Elite Explorers for $20

    Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



  3. massacre

    massacre Elite Explorer

    Joined:
    January 24, 2018
    Messages:
    577
    Likes Received:
    108
    Trophy Points:
    53
    Year, Model & Trim Level:
    1994 Explorer XLT
    From your description it sounds like the upper bolt threads may be stripped.
     
    • Like Like x 1
    • Useful Useful x 1
  4. swshawaii

    swshawaii Explorer Addict

    Joined:
    April 3, 2009
    Messages:
    9,254
    Likes Received:
    306
    Trophy Points:
    93
    City, State:
    Kailua-Oahu, Hawaii
    Year, Model & Trim Level:
    '05 Sport Trac XLS (RWD)
    • Like Like x 1
    • Thanks Thanks x 1
  5. RangerX

    RangerX Elite Ranger Staff Member Moderator Elite Explorer

    Joined:
    July 14, 1999
    Messages:
    9,564
    Likes Received:
    174
    Trophy Points:
    83
    City, State:
    Omao, Kauai
    Year, Model & Trim Level:
    '93 Ranger XLT 4X4
    Also, if you're putting the starter from the automatic onto your manual trans, I don't believe it will work, they are different.
     
    • Like Like x 1
    • Useful Useful x 1
  6. Dubious_Downfall

    Dubious_Downfall New Member

    Joined:
    July 6, 2018
    Messages:
    44
    Likes Received:
    3
    Trophy Points:
    8
    City, State:
    Bonney Lake, WA
    Year, Model & Trim Level:
    1993 Ford Explorer Sport
    Er... Shouldn't the bolt be too small for the hole if the hole is stripped? I have the opposite problem. My bolt is too big for the hole.
     
    • Like Like x 1
  7. RangerX

    RangerX Elite Ranger Staff Member Moderator Elite Explorer

    Joined:
    July 14, 1999
    Messages:
    9,564
    Likes Received:
    174
    Trophy Points:
    83
    City, State:
    Omao, Kauai
    Year, Model & Trim Level:
    '93 Ranger XLT 4X4
    Maybe the threads are not stripped in the way you're thinking, maybe they are damaged, chewed up, from the original bolt slowly backing out out and banging around over time, while driving.

    I suggest getting ahold of a tap and die set, and try to fix the threads back to original thread size and pitch. It's probably just the outer few turns that are messed up.
     
  8. BKennedy

    BKennedy Elite Loser Staff Member Moderator Elite Explorer

    Joined:
    November 29, 2000
    Messages:
    6,272
    Likes Received:
    570
    Trophy Points:
    133
    Location:
    USA
    City, State:
    San Diego, PRofK
    Year, Model & Trim Level:
    1994 XLT
    Is the original bolt broken off inside, making it seem like the other bolt is too large?

    Its possible a previous owner stripped the bolt hole, then installed a smaller diameter helicoil or other repair sleeve.
     
  9. gmanpaint

    gmanpaint Back in 5 minutes Staff Member Moderator Elite Explorer

    Joined:
    August 1, 2008
    Messages:
    9,998
    Likes Received:
    801
    Trophy Points:
    133
    City, State:
    STL MO
    Year, Model & Trim Level:
    Modified 95 XLT
    Auto starter into a manual bell housing just wont line up, and seem like it won't thread. Not only are they different sizes, the engine to trans plate is different at the starter hole.

    Stick a Phillips screwdriver into the bolt hole in the trans, and check for a snapped bolt, flashlight and mirror to check for a helicoil insert, etc...

    If all checks out well, get a manual starter, and the bolt holes will line up.
     
    • Like Like x 2
  10. Dubious_Downfall

    Dubious_Downfall New Member

    Joined:
    July 6, 2018
    Messages:
    44
    Likes Received:
    3
    Trophy Points:
    8
    City, State:
    Bonney Lake, WA
    Year, Model & Trim Level:
    1993 Ford Explorer Sport

    Going to grab a mirror from the parts store and give this a shot.

    Since I replaced the lower bolt, I haven't had any starting issues. Luckily.
     
    • Like Like x 1
  11. massacre

    massacre Elite Explorer

    Joined:
    January 24, 2018
    Messages:
    577
    Likes Received:
    108
    Trophy Points:
    53
    Year, Model & Trim Level:
    1994 Explorer XLT
    Sorry about that I thought your bolt was too small. My bad I prob misread it.
     
  12. Dubious_Downfall

    Dubious_Downfall New Member

    Joined:
    July 6, 2018
    Messages:
    44
    Likes Received:
    3
    Trophy Points:
    8
    City, State:
    Bonney Lake, WA
    Year, Model & Trim Level:
    1993 Ford Explorer Sport
    Well, my clutch started slipping like crazy, so the starter bolt is on the back burner until I get the clutch changed out. And possibly the rear main seal...
     






We Support Our Troops!