Tools You'll Need:
* Socket set: Various sizes, including deep sockets for potentially hard-to-reach bolts. Metric and SAE sockets might be needed.
* Wrench set: Combination wrenches are helpful.
* Ratchet: A good quality ratchet will make the job easier.
* Extensions: These are essential for reaching bolts in tight spaces.
* Torque wrench: To properly tighten the starter bolts to the manufacturer's specifications. This prevents damage to the starter and engine.
* Jack and jack stands: For safety, always support the vehicle properly.
* Wheel chocks: To prevent the vehicle from rolling.
* Gloves: To protect your hands.
* Wire brush: To clean the starter mounting surface.
* Penetrating oil (PB Blaster, etc.): To help loosen stubborn bolts.
* New starter: Make sure you get the correct replacement starter for your specific engine.
Steps:
1. Safety First: Disconnect the negative battery cable. Chock the wheels and use jack stands to safely support the truck.
2. Access the Starter: The location of the starter varies depending on the engine. Generally, it's located on the engine block, usually towards the bottom and somewhat hidden. You might need to remove some components to access it fully. This could include:
* Air cleaner assembly: This often needs to come off for better access.
* Exhaust components: Sometimes parts of the exhaust system need to be loosened or removed.
* Wiring harnesses: Carefully disconnect any electrical connections near the starter. Label them if necessary for easier reassembly.
* Other components: Depending on your truck's configuration, you might need to remove other items. Consult a repair manual specific to your year, make, model, and engine.
3. Remove the Starter: Once you have access, locate the starter mounting bolts. Usually, there are two or three. Spray penetrating oil on the bolts to help them loosen. Use the appropriate sockets and wrenches to remove the bolts. The starter might be heavy, so be prepared to support it as you remove the last bolt.
4. Disconnect the Electrical Connections: There will be at least one, maybe two, large cables connected to the starter. Carefully disconnect these. Take note of their position for reinstallation.
5. Install the New Starter: Clean the starter mounting surface on the engine block with a wire brush. Install the new starter, ensuring it's properly aligned. Tighten the mounting bolts to the manufacturer's specified torque.
6. Reconnect the Electrical Connections: Reconnect the electrical cables to the new starter, ensuring a secure connection.
7. Reassemble: Carefully reinstall any components you removed to access the starter.
8. Reconnect the Battery: Reconnect the negative battery cable.
9. Test: Try to start the engine. If it doesn't start, double-check all connections and ensure everything is properly installed.
Important Considerations:
* Repair Manual: A repair manual specific to your 1990 Ford Dually is highly recommended. It will provide detailed diagrams and instructions, showing the exact location of the starter and any components that need to be removed.
* Engine Type: The location and accessibility of the starter differ significantly depending on the engine.
* Safety: Working under a vehicle can be dangerous. Always use jack stands and follow safe working practices.
If you are not comfortable performing this repair yourself, it's best to take your truck to a qualified mechanic. This is especially true if you are not familiar with automotive repair. Improperly installing the starter could cause damage to your vehicle.
