Tools You'll Likely Need:
* Socket set: Various sizes, including metric and SAE (likely both).
* Wrench set: Similar to sockets.
* Ratchet: A good quality ratchet will make the job easier.
* Extension bars: To reach difficult-to-access bolts.
* Breaker bar: For stubborn bolts.
* Jack and jack stands: Essential for safety. Never work under a car supported only by a jack.
* Wheel chocks: To secure the car.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* Wire brush: To clean the battery terminals and starter connections.
* Penetrating oil (like PB Blaster): Helps loosen rusted bolts.
* New starter: Ensure it's the correct one for your engine.
* Gloves and safety glasses: Protect yourself.
* Possibly a pry bar: For stubborn starter removal.
Procedure (General Steps):
1. Safety First: Disconnect the negative (-) battery cable. This is crucial to prevent shorts and injury.
2. Access the Starter: This is the most variable step. The starter's location on your specific LeMans will dictate the steps. Generally, you'll need to access it from underneath the car. You'll likely need to remove some components to get a clear view and access to the starter mounting bolts. This may involve removing:
* Part of the exhaust system: Possibly the downpipe or other components.
* Some engine components: Depending on your specific engine and how things are mounted, you may need to partially remove or move some engine accessories. Consult your repair manual.
* Possibly the motor mounts: It's less likely, but some models might require partial motor mount removal.
3. Disconnect the Starter Wiring: Carefully disconnect the electrical cables from the starter solenoid. Take pictures or make notes of how they connect to ensure correct reassembly. Tag wires if necessary.
4. Remove the Starter Bolts: Usually there are two or three bolts securing the starter to the engine block. Apply penetrating oil if necessary and allow it to soak for a while. Use the appropriate sockets and wrenches. These bolts can be extremely stubborn due to corrosion. A breaker bar may be needed.
5. Remove the Starter: Once the bolts are removed, the starter should come loose. It might be stuck due to corrosion. Gently rock it back and forth while pulling it out. A pry bar might be needed, but use it carefully to avoid damaging the starter or the engine block.
6. Install the New Starter: Carefully align the new starter with its mounting holes. Install the bolts and tighten them to the manufacturer's specifications (consult your repair manual).
7. Reconnect the Wiring: Reconnect the electrical cables to the new starter, making sure they are securely attached.
8. Reinstall Components: Reinstall any components you removed to access the starter (exhaust, engine components, etc.).
9. Reconnect the Battery: Reconnect the negative (-) battery cable.
10. Test the Starter: Start the engine to verify that the new starter is working correctly.
Important Considerations:
* Repair Manual: This is absolutely crucial. A Haynes or Chilton manual specific to your 1966 Pontiac LeMans 6-cylinder is your best friend for this job. It will provide detailed instructions, diagrams, torque specifications, and other essential information.
* Corrosion: Older cars suffer from corrosion. Expect to spend time freeing up rusted bolts.
* Safety: Always prioritize safety. Use jack stands, chocks, and work in a well-lit area.
* Photography: Take lots of pictures as you disassemble things. This will help immensely during reassembly.
This is a general overview. The exact procedure will vary depending on your car's specific configuration. Without a repair manual specific to your vehicle, attempting this repair is strongly discouraged. If you're uncomfortable with this type of work, it's best to take your car to a qualified mechanic.
