Could someone please list any tools that may be particularly handy, or required to perform a starter replacement on a 2012 GC SXT 3.6L outside of a general set of 3/8" drive sockets & some wrenches. I saw that the manual says to take off the front cat & go at it from the front, but I think I may go in from underneath laying on my back. If someone can mention nut/bolt sizes, you'll save me multiple trips from under the vehicle. I'd take them all, but the dolly has a hard time rolling over a pile of scattered tools.
Any tips on tools, or technique would be appreciated.

PS, Any advice on what brand of reman, or just go with a new unit?

 

If you can get the starter out without removing the cat, then certainly do it. However it’s always best to be prepared so I’d recommend having gaskets and replacement bolts ready for the cat just in case - you can always return the parts if you don’t need them. It was hard to tell from the diagrams I was looking at (and I’m yet to replace a starter on a 3.6) but it appeared the starter is positioned in a place where there’s not enough clearance between the cat and engine to remove it. Additionally it looks like the front mount and bracket need to be removed to access the starter mount bolts.

Others will argue this I’m sure, but in my experience, reman is just as good as new. At work we install BBB brand starters (they do both new and reman) and we’ve never had to replace one due to failure.

Additional tools/supplies to consider (you won’t necessarily need all of this - use your own judgement):

1) Good work gloves and safety glasses (one law of working under cars - crap will always get in your eyes the moment you can’t remove your hands from your work )
2) Penetrating oil and/or parts cleaner
3) Disposable shop rags
4) Fine grit sandpaper, emery cloth or scotch brite pad for cleaning gasket surfaces
5) Handheld and/or drill mount wire brushes
6) 3/8” breaker bar
7) Assortment of 3/8” extensions
8) Standard set of 1/4” drive sockets (When working in confined spaces, I often find that I’ll have to use a 3/8” drive to break a bolt loose but then it’s easier to use a 1/4” drive to continue removing it)

As to bolt sizes, everything from the factory is metric (if you have SAE bolts on it, a PO is to blame). I’m not swearing any of this is true for your van, but some common sizes are:

Starter bolts - 15
Exhaust/Cat - 13, 15
Engine mount - 15, 17, 18
Other common sizes - 8, 10

Good luck.

#4 are starter mount bolts