Starter Motor

Disassembly

1. Remove nut and disconnect wire to solenoid M-terminal.

2. Remove screws securing starter solenoid (11390) to drive end housing. Remove starter solenoid and shims.

3. Remove thru bolt (11091) and brush holder screws from brush end plate and bushing (11049).

4. Remove brush end plate and bushing. Do not lose spring washer inside of brush end plate and bushing.

5. Lift brush springs for the field coil brushes and remove field coil brushes from brush holder (11061). Remove brush holder.

6. Remove starter motor armature (11005) and frame from drive end housing. Remove steel ball from gear end of starter motor armature.

7. Remove center plate, seal ring, and gear assembly from drive end housing.

8. Turn drive end housing so pinion end is up.

9. Set socket of appropriate size on stop ring and strike socket with a hammer, pushing stop ring down onto shaft, revealing snap ring.

   

10. Use duck-bill snap ring pliers to expand snap ring and remove from starter drive shaft.

11. Remove stop ring, pinion and spring.

12. Remove lever packing.

13. NOTE: Lever pivot plate is held in the drive end housing with interference tabs which press against the side of the housing. Springs may jump out when pivot plate is pried loose.

    Note position of pivot plate. Cover open end of drive end housing with rags, then pull loose pivot plate with pliers, and catch springs.

    

14. NOTE: Do not disassemble the starter drive (11350) from output shaft (11355), but replace as an assembly.

    Remove drive end housing, output shaft, and drive lever and pin (11067) together. Note direction of drive lever and pin and remove drive lever and pin from starter drive.

15. Perform cleaning and inspection procedures. Refer to Section 03-06.

Assembly

1. NOTE: During assembly, lubricate all sliding parts, pivot points, and gear teeth with Multitemp MS No. 2 or equivalent lubricant.

   Apply Multitemp MS No. 2 lubricant or equivalent inside of rear drive end housing bearing before assembly.

2. Position drive lever and pin in collar on starter drive.

3. Install drive end housing with assembled output shaft and starter drive into drive end housing.

4. Install two springs onto drive lever and pin.

5. NOTE: If the interference tabs on the pivot plate prevent reinstalling the plate, file off the tabs or use a new pivot plate.

   Install pivot plate and packing. At this point the packing is the only thing holding the springs in place.

6. Install spring, pinion, and stop ring. Press down the stop ring and, using duck bill snap ring pliers, expand the stop ring retainer and put in place.

7. NOTE: Because the packing is the only thing retaining the drive lever and pin and springs, install the drive end housing before the frame assembly to assure starter solenoid, springs, pivot plate, and packing are properly positioned.

   Install starter solenoid and same number and thickness of shims as removed, to drive end housing. Tighten to 5-7 Nm (44-62 lb-in).

8. Install steel ball in end of armature shaft.

9. Install starter motor armature, inserting gear end of armature shaft into output shaft. Make sure steel ball does not fall out.

10. Install frame assembly.

11. With ground brushes out of their slots in brush holder, set brush holder onto armature commutator.

12. Using long-nose pliers, pull up brush springs and insert field coil brushes into their respective slots.

13. Using long-nose pliers, pull up brush springs and insert ground brushes into their respective slots.

14. Install the spring washer onto the nose of the starter motor armature.

15. Install the brush end plate and bushing and install the brush end plate-to-brush holder screws. Tighten to 2-3 Nm (18-27 lb-in).

16. Install the thru bolts and tighten to 8-10 Nm (71-89 lb-in).

17. Install wire on solenoid M-terminal. Install nut and tighten to 10-12 Nm (89-106 lb-in).

18. Check pinion gap as outlined in this section and adjust if necessary.