I was finally able to isolate the engine noise on my car…
Just to refresh, this noise would start and linger or sometimes
subside a bit. Rarely, it would disappear all together…
It sounded like metallic scraping, clicking, squealing, rubbing.
Using stethoscope I listened and could not isolate it. I could hear
it from every part of the engine. It didn’t sound good to be honest.
Well, I tried the simple things first. Removed the drive belt to
eliminate A/C compressor, Alternator, and P/S pump, and their pulleys.
Noise still there…Next, I checked the timing belt area. Timing marks
still ok. Removed the timing belt. It was fine. Two tensioner pulleys were ok
as well. Hydraulic tenssioner appeared collapsed, and I saw signs of oil
leakage. Replaced it, and put everything back together. Noise still there…
With my head under the hood, and the engine idling, I tried to focus
on this darn noise. Just for grins I got a long wooden dowel, put one end
on top of starter motor and hit the other with hammer. Noise stopped
instantly?! Turned off/on the engine. Noise reappeared. Hit the starter
again, and the noise went away…Eureka!!! It must be the starter.
Got a new one and followed installation steps posted here. Took
about 2-3 hours. I was careful…Now, I could easily do it in 1-1.5 hours.
Well, car runs great again. Darn starter, it obviously wasn’t retracting
all the way. Live and learn…

Calvin! My man! A BF Hammer works again!

But why did you think a good spanking would do it? LOL

Klaus
--
Proud owner of a 220S. If I had more room, I would have more Volvos.

Indeed! If in doubt, use the hammer........carefully.

Great write-up! Thanks for the helpful info!

Any idea about whether the old starter could have been refurbished in any way to allow it to stop the squealing? Like taking a wire-wheel to the shaft and lubing it up, or something like that? It would be nice if you could lend your ideas about what might cause this to happen to a starter and get some advice about whether this definitely requires a new starter or not.

What did you pay for a new starter? And where did you get it? And how is the quality (superficial inspection quality, obviously)? I see the Bosch on FCP is ~$185 - does that sound close?

--
1998 V70 AWD->FWD Turbo 200k+

Old starter had chewed up teeth, warn out bushing,
and scarred shaft. Also, the brushes were almost gone,
while the bearings also appeared warn. This starter was
not worth fixing. I traded it in for a rebuilt OEM that came
with life time warranty. Most places on internet only offer
1 year warranty. Plus it was about $ 50 cheaper, and I didn’t
have to wait. Local store had it in stock.
The one that failed was Bosch?! I also own two RWD Volvos,
both 6 years older, with original starters in great condition.
Go figure…

I would guess that MOST of the damage happened after it hung up and would not release.
That makes it turn MUCH faster, not to mention longer, than it was ever designed for.
--
George Downs, Bartlesville, Heart of the USA!