Ford 555 Starter Removal Access Strategy and Electrical System Considerations

[MikePhua]

The Ford 555 and Its Legacy in Backhoe Loader Design
The Ford 555 backhoe loader was introduced in the late 1970s and remained in production through the 1980s under Ford’s industrial equipment division. Known for its rugged drivetrain and straightforward hydraulics, the 555 became a staple in municipal fleets, farm operations, and small construction outfits. Powered by a 3-cylinder or 4-cylinder diesel engine depending on the variant, the machine featured a mechanical shuttle transmission and a 12V electrical system with a gear-reduction starter mounted low on the engine block.
Terminology annotation:

• Starter Motor: An electric motor that engages the engine flywheel to initiate combustion.
  
• Solenoid: An electromagnetic switch mounted on the starter that controls current flow from the battery.
  
• Shuttle Transmission: A gearbox allowing quick forward-reverse shifts, often used in backhoe loaders.
  
• Bellhousing: The cast enclosure between engine and transmission where the starter engages the flywheel.
  

In Ohio, a township mechanic was tasked with removing the starter from a 555 that had begun clicking but failed to crank. The machine was parked on soft ground, and the loader arms were down, complicating access to the lower engine components.
Starter Location and Access Challenges
The starter on the Ford 555 is mounted on the right-hand side of the engine, tucked between the frame rail and the bellhousing. Access is partially obstructed by the loader frame, hydraulic lines, and in some cases, the battery box or fuel tank. The starter is held in place by two or three bolts, typically 9/16" or 5/8", and may require a combination of socket extensions and universal joints to reach.
Access strategy:

• Raise loader arms and secure with safety lock or blocking
  
• Disconnect battery ground cable to prevent accidental short
  
• Remove side panels or battery tray if obstructing access
  
• Use long-handled ratchet with wobble extension to reach upper bolt
  
• Support starter from below before removing final bolt to prevent drop
  

Recommendations:

• Spray mounting bolts with penetrating oil 30 minutes before removal
  
• Use magnetic tray to hold bolts and prevent loss in frame cavities
  
• Keep starter supported with strap or jack during removal
  
• Inspect mounting flange and flywheel teeth before reinstallation
  
• Replace starter bolts with grade 8 hardware if threads are worn
  

In Alberta, a contractor used a flexible ratcheting wrench to reach the top starter bolt after removing the hydraulic return line bracket. The job took under an hour with proper tools and planning.
Electrical Connections and Solenoid Inspection
The starter solenoid receives 12V from the ignition switch and directs high current from the battery to the motor. On the Ford 555, the solenoid is mounted directly on the starter body, with two large terminals and one small signal wire. Corrosion, loose terminals, or frayed wires can mimic starter failure.
Electrical checklist:

• Disconnect battery before touching any terminals
  
• Inspect cable ends for corrosion or heat damage
  
• Clean terminals with wire brush and apply dielectric grease
  
• Test solenoid continuity with multimeter before removal
  
• Label wires if multiple connections are present
  

Recommendations:

• Replace battery cables if insulation is cracked or terminals are loose
  
• Use heat-shrink terminals for improved vibration resistance
  
• Check ignition switch output voltage during crank position
  
• Keep spare solenoid and terminal nuts in field inventory
  
• Document wire routing and terminal orientation for reinstallation
  

In Georgia, a fleet technician discovered that the starter cable had rubbed against the loader frame, causing intermittent shorts. After rerouting and replacing the cable, the starter performed flawlessly.
Starter Bench Testing and Replacement Options
Once removed, the starter can be bench-tested using jumper cables and a 12V battery. The motor should spin rapidly and the drive gear should extend smoothly. If the starter fails to engage or spins weakly, internal brushes, bearings, or windings may be worn. Rebuild kits are available, but many owners opt for replacement due to labor cost and downtime.
Testing procedure:

• Clamp starter securely to bench or vise
  
• Connect negative cable to starter body
  
• Touch positive cable to solenoid input terminal
  
• Use jumper wire to energize solenoid signal terminal
  
• Observe gear extension and motor speed
  

Replacement options:

• OEM Ford industrial starter (if available)
  
• Aftermarket gear-reduction starter with higher torque
  
• Rebuilt unit from local auto electric shop
  
• Cross-reference part number with tractor or truck equivalents
  

Recommendations:

• Verify tooth count and rotation direction before ordering replacement
  
• Compare mounting flange and bolt pattern with original unit
  
• Use anti-seize on mounting bolts during installation
  
• Torque bolts to spec and check for flywheel clearance
  
• Retest system voltage and starter draw after installation
  

In Michigan, a farmer replaced his 555 starter with a gear-reduction unit from a diesel truck application. The new starter cranked faster and drew less current, improving cold-start reliability.
Preventative Measures and Long-Term Reliability
To avoid future starter issues on the Ford 555:

• Inspect battery cables and terminals monthly
  
• Keep loader arms raised during service for better access
  
• Clean starter body and solenoid terminals annually
  
• Monitor cranking speed and listen for gear engagement
  
• Replace starter proactively every 3,000–4,000 hours if used daily
  

Recommendations:

• Add battery disconnect switch for safety and theft prevention
  
• Use sealed starter if operating in wet or muddy conditions
  
• Keep starter part number and wiring diagram in service manual
  
• Train operators to report slow cranking or clicking immediately
  
• Maintain log of electrical repairs and component replacements
  

In Maine, a municipal crew added a battery disconnect and upgraded the starter wiring on all 555 units. The result was fewer no-start calls and improved service access during winter.
Conclusion
Starter removal on the Ford 555 is a manageable task with the right tools, preparation, and understanding of the machine’s layout. While access can be tight, strategic disassembly and electrical inspection make the job straightforward. Whether rebuilding or replacing, attention to mounting, wiring, and testing ensures reliable starts for years to come. In legacy iron like the 555, every bolt and wire tells a story—and every start begins with a clean connection.