I've heard that one must remove the y-pipe(factory dual cats) in order to remove the starter on a A4 equipped car. Just wondering if anyone has done this w/o removing the pipe. The other day, we left a restaurant and all it did was just click...power to the solenoid, not to the starter motor. Found a metal rod and tapped the starter until it started. Started fine the next time, but I ordered a solenoid for replacement, so I need to pull the starter somehow. I searched the topic and found some info....mainly the starter is a PG260m, with straight bolt alignment, not angled, 11tooth pinion, 153tooth ring, and that hopefully the marine version solenoid will work on it. The FSM starter section is useless.

 

It can be done and here's how. Unbolt the starter and its two electrical connections. Remove the trans inspection pan(4 bolts). Move the starter forward and turn it upside down. Remove the 2 bolts for the exhaust pipe connection near the inspection cover and slide the rear flange back on the pipe. The transmission cooler lines have to be massaged a bit and starter can be slid out between them and the exhaust pipe. That's it.... After finding I couldn't get heat to the 3rd nut on the driver's cat, I put the other two nuts back on and found plan 'b'.

Now to find some inverted torx sockets to find out if the starter needs more than a solenoid.

 

Well, we have good news. The starter motor is fine, no other issues. I got the marine solenoid in and it's a perfect match, except for one extra terminal for an ignition resistor bypass(not used on the LT1). Here's the Delco part# 1114583. So, for ~$25, she's on the road again. Screw the FSM which states the starter isn't serviceable. Of course if it had other issues, I guess a new Chinese replacement would be the only ticket, since Delco doesn't make new ones now...

 

Just want to say thanks.. First tried removing crossover pipe, but it wasn't budging.. Thought I'd never get that dang starter out until read your post.. Tight fit but got it out.. Jacked up tranny just a hair to help squeeze that thing through too..