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Successful Starter Removal on '01 Passport 4WD 3.2


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XR400R
08-09-2009, 04:07 PM
Many, many posts have described the difficulty in removing the Lt exhaust pipe section in order to remove/replace the starter on a 2nd gen. Rodeo/Passport with 4WD.

I managed to accomplish it this weekend using PB Blaster and an air impact wrench. I first soaked the nuts overnight in PB, then hit them with 250 ft/lb from the air gun. It took every thing the air gun would put out, and still only released VERY, VERY slowly. I can't believe I didn't break the studs or back them completely out of the header! And I used NO HEAT to aid in extraction.

The most difficult thing about the whole process was releasing the small motor-side clip on the top of the solenoid. Couldn't see it, only feel it. That took a while.

Many thanks to all the posters on this forum who previously addressed this subject! Your experience/tips enabled my successful extraction.

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