Section 03-06A: Starting System, Gasoline Engines | 1996 F-Series and Bronco Workshop Manual |
NOTE: Although disassembly and service procedures are shown for the starter motor in this section, it is recommended that the starter motor (11001) be returned to Ford Return Parts Division for analysis and review.
| Item | Part Number | Description |
|---|---|---|
| 1 | N805403 | Terminal Nut |
| 2 | 11390 | Starter Solenoid |
| 3 | 11A171 | Seal |
| 4 | 11130 | Drive End Housing |
| 5 | N805405 | Solenoid Screw (2 Req'd) |
| 6 | 11001 | Starter Motor |
| 7 | 11135 | Bushing |
| 8 | 11A196 | Drive End Housing Seal Ring |
| 9 | 11005 | Starter Motor Armature |
| 10 | 11A172 | Armature Thrust Ball |
| 11 | 11A167 | Planet Gear Retainer |
| 12 | 11K190 | Planet Gear |
| 13 | 11355 | Output Shaft |
| 14 | 11A165 | Stationary Gear |
| 15 | 11036 | Pinion Thrust Washer |
| 16 | N805404 | Truarc® E-Ring |
| 17 | 11067 | Drive Lever and Pin |
| 18 | 11350 | Starter Drive |
| 19 | 11180 | Drive End Housing Seal |
| 20 | 11223 | Stop Ring Retainer |
| 21 | 11222 | Starter Drive Stop Ring |
| 22 | — | Magnet Pole Piece (6 Req'd) (Part of 11075) |
| 23 | — | Pole Shunt (6 Req'd) (Part of 11075) |
| 24 | — | Magnet Retainer (6 Req'd) (Part of 11075) |
| 25 | 11075 | Starter Frame and Magnet |
| 26 | 11061 | Brush Holder |
| 27 | 11059 | Brush Spring |
| 28 | — | Bushing (Part of 11049) |
| 29 | 11049 | Brush End Plate and Bushing |
| 30 | N805406 | Brush Plate Screw (2 Req'd) |
| 31 | N805428 | Through-Bolt (2 Req'd) |
Disassembly
Remove positive brush connector from solenoid (M) terminal.
Remove retaining screws and starter solenoid.
Remove through-bolts and separate drive end housing from starter frame. Remove housing seal assembly from drive end housing. Remove drive and gear assembly from drive end housing.
Remove drive lever from starter drive (11350). Remove starter drive stop ring (11222) and stop ring retainer (11223) from output shaft (11355), then remove starter drive from shaft assembly. Push Truarc® E-ring off stop ring retainer, and separate stationary gear (11A165) from output shaft.
Remove brush plate screws and brush end plate from starter frame. Remove brush holder (11061) and push armature assembly out of starter frame.
Assembly
Install armature in starter frame.
Apply a thin coating of Ford Teflon® Lubricant D2AZ-19590-A or equivalent meeting Ford specification ESB-M1C111-A on both ends of armature shaft and spline.
Install brush holder. Make sure brushes fit over armature commutator.
Apply grease to bushing bore in brush end plate.
Push back grommet onto starter frame and attach brush end plate with brush plate screws. Tighten to 2.3-3.4 Nm (20-30 lb-in).
Apply grease to output shaft spline and place stationary gear over shaft assembly.
Install pinion thrust washer (11036) and push Truarc® E-ring onto shaft assembly.
Place starter drive onto output shaft and install starter drive stop ring and stop ring retainer.
Attach drive lever to starter drive.
Grease and install planet gears (11K190).
Apply grease to drive end housing bushing bore (approximately one-quarter full).
Install drive gear assembly into drive end housing, making sure to line up bolt holes in drive gear assembly and drive end housing.
Place planet gear over drive gear assembly.
Install housing seal assembly into drive end housing.
Position starter frame to drive end housing and install through-bolts. Tighten to 5.0-9.5 Nm (45-84 lb-in).
Correctly position starter solenoid (11390) to drive end housing. Make sure that solenoid plunger is attached through drive lever (bottom solenoid terminal (M) should have a metal strip attached to it). Tighten starter solenoid bolts to 5.1-9.6 Nm (45-85 lb-in).
Attach positive brush connector to starter solenoid (bottom terminal). Tighten nut to 9-13.5 Nm (80-120 lb-in).
Check that starter motor no-load current draw is within specification. Refer to Section 03-06 for testing procedures.