03-53 Auxiliary Systems
03-53
STARTER, PERMANENT MAGNET DISASSEMBLY AND ASSEMBLY (Continued)
Starter Drive Replacement Armature Replacement
1.
2.
3.
4.
5.
6.
7.
8
.
Remove positive brush connector from solenoid
motor “M” terminal. Remove solenoid retaining
screws and remove solenoid.
Remove through-bolts and separate motor
assembly drive end housing. Remove housing
seal from drive end housing. Remove drive gear
assembly from housing and detach drive lever.
Remove stop ring and retainer from driveshaft
and then remove drive assembly.
Apply a thin coating of ESF-Ml C218-A Grease,
or equivalent low temperature grease, on
driveshaft spline. Install new drive gear assembly
on driveshaft. Install new stop ring and retainer.
Attach drive lever.
Partially fill drive end housing bearing bore with
grease (approximately one-quarter full). Install
drive gear assembly in housing, making sure to
line up bolt holes in gear assembly and housing.
I nstal
housi
I leve
w
r support and housing seal in drive end
Position starter frame to housing and install
through-bolts. Tighten to 5.0-9.5 Nom (45-84
in-lb).
Install solenoid. Refer to Assembly.
5.
Remove positive brush connector from solenoid
motor “M” terminal.
Remove through-bolts and separate motor from
gear assembly and drive end housing.
Remove brush end plate screws, brush end plate
and brush assembly from starter frame. Remove
armature from frame.
Install new armature in frame. Apply a thin
coating of ESF-Ml C218-A Grease, or equivalent
low temperature grease, on both ends of
armature shaft and pinion.
Install brush assembly. Using tool, make sure that
brushes fit over commutator. Push black
grommet onto frame. Apply grease to bearing
bore in brush end plate and attach to starter
frame.
Position starter frame to gear assembly and drive
end housing and install through-bolts. Tighten to
5.0-9.5 Nom (45-84 in-lb).
Attach positive brush connector to solenoid
(bottom terminal). Tighten nut to 9-13 Nom
(80-I 20 in-lb).
Check that starter no-load current draw is within
specification. Refer to Bench Testing.
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