[pepperjack13]

I have been trying to remove the 2 bolts holding the starter in place but they just won't come off! I already broke two sockets and they haven't moved one bit. I tried spraying WD40 but I am not sure it's going to work because thread is propably only in the lower end. Can somebody give me some tips on how to take the suckers off???

There's little space down there so I feel like I don't have many options other than keep trying.

 

[aztrojans12]

Nail them with PB blaster that stuff is the best. Hit the bolts with PB blaster the night before and let it sit. Then spray again a little before you start to work on the car. I think when I replaced my starter, I just used a wrench and tapped it with a rubber mallet to loosen up the bolts.

 

[tkemme]

Use a long extension (8-12 inches) to get your socket handle up above the EGR valve and other junk. A wobble type is ideal......way easier than trying to cram your hands down there.

 

[pepperjack13]

@aztrojans12 isn't Pb blaster the same as wd40? I still going to try to spray some of that stuff today and how were you able to find space for the rubber mallet? I thought about doing just that but couldn't find a way to do it

@tkemme- I guess I am going to have to get one of those

How did you guys get the bolt that is towards the front of the car off? a ratchet with a socket doesn't fit and with a wrench is still very hard.
Also I have seen that by heating up the bolts you can also get them off so if I leave the car running for 15-20 mins do you think that would help?

 

[supared]

@pepperjack13
First, wd-40 is not the same as PB blaster, which has penetrating properties. Blaster will help if you spray it on there liberally and leave it overnight.

I imagine you have removed the air intake accordian hose, cuz you have too. You also want to remove the battery and battery tray. Like tkemme said, you will need a long extension or several short ones will work. I used a long breaker bar with an impact socket since it is a very strong heat treated chromoly steel. There are two bolts. It gets cramped, but you can get them. You might consider removing the air box if you still have trouble.

Don't warm the car up like that, or you will burn the crap out of yourself trying to get in there.

Good luck!

 

[aztrojans12]

PB blaster is not like WD40. PB blaster can actually "crawl" up threads, it defies gravity so to speak. WD40 does not to that. As mentioned by supared, I don't know what all you have removed, but when I removed my starter I removed my intake, battery, and tray. With all that out of the way I had room. I think I put a big wrench over the bolt, and then used another wrench to connect to the end of the big wrench for added leverage and space. Then, I just nailed it with the mallet and they popped loose no issues at all.

@aztrojans12 isn't Pb blaster the same as wd40? I still going to try to spray some of that stuff today and how were you able to find space for the rubber mallet? I thought about doing just that but couldn't find a way to do it

@tkemme- I guess I am going to have to get one of those

How did you guys get the bolt that is towards the front of the car off? a ratchet with a socket doesn't fit and with a wrench is still very hard.
Also I have seen that by heating up the bolts you can also get them off so if I leave the car running for 15-20 mins do you think that would help?

 

[pepperjack13]

Thanks guys for all your help. I was finally able to remove the starter. I had to remove the air box/intake hose to get one of the bolts and an extension to get the other one. But I discovered something that looks really bad.

When I removed the old starter I noticed that the teeth of what I think is the flywheel (correct me if I am wrong) were very worn but the ones from the starter didn't look that bad. But I thought that maybe, just maybe the new starter was going to work just fine.

But it didn't. The car still make this loud noise that I assume is caused by the teeth of the gear in the starter trying to make contact with the worn teeth from the flywheel in the engine. The car starts but you usually have to try several times (just like with the old starter).

Now I am very worried about this because it looks to me that you have to take apart the engine to replace the flywheel. And that sounds VERY expensive considering that I bought the car a couple of weeks ago. Can somebody tell me how hard or expensive it is to replace what I assume is the flywheel?

 

[fly757]

Removing the transmission is no simple task. Been there, done that. Get some help if it's your first time.

 

[Oppa]

.......WAIT!....you just got the car a couple of weeks ago!?

Didn't you get some kind of warranty from the dealer? New or Used...there should be some kind of dealer warranty that comes with the car in case the car's a lemon. UNLESS it was stated that the vehicle was "sold as is"...then NVM.

I would demand the dealer to fix the issues.

 

[pepperjack13]

@fly757 I agree with you, there is no way I could do such a job by myself even though I would like to just to save some $$$

@SANDMAN.3 I didn't buy it from a dealer, I bought it from some guy who had owned it for like 4 or 5 months (international student couln't find a job after buying the car). When my friend and I took it for a test drive about 3 weeks before buying it we notice the started making a little bit of noise but the car always started on the first try. I took it to a mechanic right before I bought it and he said that it needed a new starter so I negotiated the price with the owner accordingly.

Isn't replacing a flywheel almost the same as replacing the clutch?

 

[aztrojans12]

Yes, replacing the flywheel is almost the same as replacing the clutch. How many miles are on the car? I have around 106,000 miles on mine with the original clutch. My starter doesn't engage maybe once every couple weeks I am assuming because some of the flywheel teeth are worn down. But, it starts on the 2nd try whenever it does that. I am just going to deal with it until I replace the clutch. Does your car do this everytime you try to start it, or just occassionally?

 

[aztrojans12]

And a side note, you will want to replace the clutch when you replace the flywheel. A good clutch kit and flywheel will cost you somewhere around $600-$800. Labor is expensive, and depending who you know or where you go, expect to pay somewhere in the range of $500-$900 for labor.

 

[pepperjack13]

Thanks aztrojans12 for the info. The car has 103,000 mi and it happens almost every time (once in a while it starts on the first try). But it always makes noise.

I found an exedy clutch kit on ebay for like $165 and the flywheel, a used one from car-parts.com goes for $50-$125. Do you guys recommend buying these parts from such places?

EXEDY OEM CLUTCH KIT 03-07 MAZDA 6 3.0L - eBay (item 360330832926 end time Jan-22-11 11:49:33 PST)

 

[flipper66]

How to: remove starter from mazda 6 3.0L - 6Crew.com Forum

write up I did on how to remove the starter.

Ive done it 4-5 times atleast between a few different cars and never had a problem breaking anything.

 

[aztrojans12]

Thanks aztrojans12 for the info. The car has 103,000 mi and it happens almost every time (once in a while it starts on the first try). But it always makes noise.

I found an exedy clutch kit on ebay for like $165 and the flywheel, a used one from car-parts.com goes for $50-$125. Do you guys recommend buying these parts from such places?

EXEDY OEM CLUTCH KIT 03-07 MAZDA 6 3.0L - eBay (item 360330832926 end time Jan-22-11 11:49:33 PST)

I would go with a clutch masters stage 2 kit, just my own personal preference. But I think you will be fine with that Exedy clutch kit. However, I would definitely buy a new flywheel, I wouldn't risk buying a used flywheel. It's an expensive job to replace your clutch, last thing you need is to have to do it again soon because you used a used flywheel. I know the flywheel is like $350 new, but I would just suck it up and pay the extra $ and get it done right the first time.

 

[supared]

@pepperjack13

Our cars are known to make a short squealing sound upon cranking. It is said to be due to the buildup of clutch dust in the starter. I would doubt your flywheel teeth are damaged. Usually it is starter teeth that get stripped (not on our cars, but in general). But you never know until you check it out I guess.

You could pick up a lightweight flywheel for about $350 from either Exedy or Fidanza. I got the Exedy, but the Fidanza can be a little cheaper, weighs less (about 8lbs less !), and it has replaceable steel inserts that the flex plate squeezes the clutch disc between. The inserts can be found for about $40-$50 which totally beats buying another flywheel if you have issues.

Clutch, flywheel, headers, cai, and rear motor mount took me and another guy, burkerre about 35 hours.

I have a clutchmasters Stage 4 and I love it. It is a much lighter engagement over stock due to slightly different pivot points in the flex plate. The stage four took some getting used to - it grabs uber fast. So, I can recommend a Clutchmasters clutch, but the Exedy should be ok. Get it cheaper on Amazon ~ $130!

Amazon.com: EXEDY MZK1001 OEM Replacement Clutch Kit: Automotive

Good Luck!

 

[pepperjack13]

Thanks guys for your recommendations. A huge factor in my case is money because I spent all my savings in buying the car and on insurance (which I just found out that because I moved a couple of days ago is going to go up like $150). I would really like to follow your advise (buying a new flywheel, stage 1 or 2 clutch) but I would have to wait at least 3 months to be able to afford everything.

Given my situation the most affordable and only option right now will be getting a used flywheel and the exedy oem replacement clutch kit. Flywheels are "supposed" to last a long time so a used one, in good conditions, will probably be just fine. Plus whatever money I save by going the cheaper route will go towards buying headers (last thing I need is a blown engine).

@supared thanks for the link, it would have never occurred to me to check amazon. When I removed the starter I could see the teeth of the flywheel worn to about half of their original size (width and height wise) if not more. The starter's teeth only had a little bit of wear. It's hard to believe the starter lasted longer than the flywheel but I guess it's just one of those things.

 

[pepperjack13]

A little update...

Yesterday I decided to take off the used starter and install the original one because at least that one worked, once in a while but it worked. I took a better look at the flywheel and isn't as bad as I though it was, the starter should still be able to engage even if it is a little bit worn.

While comparing both starters side by side trying to figure out why none of them engages the flywheel I noticed that the gear in the used starter moves side to side but has trouble moving all the way to the left, right where it needs to be to engage the flywheel. Then I checked the original starter and the gear is stuck halfway, it doesn't move at all. So I think I don't need a flywheel after all!!! Just a starter that works.

If the starter in your car doesn't always engage maybe it is having the same problem.

 

[Spidy]

My clutch is slipping too... I'm shopping around for a clutch/flywheel combo. Its a bit of a mixed feeling, cause no one likes putting out money -- but at same time at 153,000km I guess its time for the clutch to go. But I'm looking forward to upgrading parts... i'm thinking the exedy with the exedy lightweight flywheel combo.