Am installing a starter motor. I have to remove the old bushing from the transmission and then install the new bushing and new starter. The bushing is 11mm interior c. How do I get the old bushing out? And the new bushing in? I have removed the old starter and purchased the new one. Starter is a Bosch. The engine is a 1985 VW (Pathfinder) diesel located in a 38' sailboat.
I wouldn't replace this bushing unless it's obviously worn out. I know of this recommended method when a puller is not available, pack the bearing bore with grease and use a socket and extension or similar rod that fits snug as possible in the bearing bore and hit this tool with a hammer as to use a hydraulic effect. the pressure of the grease will push the bearing out. This method is used on, rear wheel driven, flywheel bushing removal. Good luck!
SOURCE: starter motor
Hey..........I was having problems with my starter this summer as well I ended up putting 6 starters in. Every time you buy a starter for this car it should come with a new bushing.......the bushing is hard to get out but must be replaced. And yes you will need a bushing extractor tool which you should be able to rent from your car parts store and then return for a full refund when your done. If you have any more questions let me know. Like I said I have put six starters in my VW Jetta. I could do it with my eyes closed.
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Sara
SOURCE: 1985 VW Jetta Diesel, problem with lights. The
check head lights and tail lights relay.replace fan relay.check ac compressor make sure its getting power. if all good have ac check to make sure it have the right amount refrigerate in system.
SOURCE: how to remove vw bug starter
The starter is attached to the transmission forward of the motor. Disconnect the power cables on the starter solenoid and take a wrench to the bolts holding the starter in place - I think the wrench size is 13". It should come out very easy. Oh, be sure to disconnect the battery so you don't short something out.
SOURCE: How do I remove the starter motor bushing?
The best way I have found is to use a small flat blade screwdriver to break the bronze bushing apart, but becareful of the bellhousing. The bronze bushing will break apart pretty easy. Of course, VW makes a tool to remove it, which is about impossible to find. I have heard of taking a tap and tapping some threads into the bushing and then screwing a bolt into it and trying to pull it out.
Testimonial: "Hey thanks alot, that was great info. My advise to anyone else that ownes one of these is: "Call a Wrecker" These cars are a piece of Sh_t & there a pain in the A_ _ to work on!"
Fig. After the negative battery cable is disconnected, remove the
wire terminals from the starter solenoid
Fig. Remove the lower starter mounting bolts...
Fig. ...followed by the upper bolt, then remove the starter
from the transaxle housing
Fig. Lower starter bolt locations-1994 2.0L, 2.0L ABA
Fig. Remove the upper starter bolts
Fig. Mark the location and length of each starter bolt
Fig. Remove the starter
Fig. Close up view of the starter drive gear
Fig. When the solenoid is energized the starter drive is pushed
out and meshes with the flywheel to crank the engine
Fig. Lower starter bolt locations-1994 2.0L, 2.0L ABA
Fig. Remove the upper starter bolts 
Starter removal—4.8L, 5.3L and 6.0L engines
Exploded view of the starter motor—6.5L engine 111 views
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