Assembly Procedure

1. Install the magnets (1) in the housing:
^ Use a soft drift in order to seat the magnets in the housing.
^ Install the retainer.

Starter Motor Overhaul: Disassembly Procedure:

2. Install the gear reduction unit shield to the housing.




3. Carefully pry apart the shift lever legs (4) in order to install the lever to the drive gear.
4. Install the drive gear (3) and the retainer collar to the gear reduction unit.
5. Install the drive gear retainer.
6. Snap the drive gear retainer collar onto the retainer using a plastic tool.




7. Install the brush holder plate (2) using a piece of pipe or a socket (1) about 32.0 mm (1.25 in) in order to retain the brushes.

Starter Motor Overhaul: Disassembly Procedure:

8. Install the following components to the armature:
^ The thrust washer (2)
^ The shield (3)
^ The seal (4)
^ The washer (5)




9. Install the armature C clip (3).
10. Install the bearing housing (1).
11. Install the bearing housing screws (2).

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten
Tighten the screws to 1.8 N.m (16 lb in).




12. Lightly tap the brush holder (1) in order to seat in the housing and to install the armature with the holder.

Starter Motor Overhaul: Disassembly Procedure:

13. Push in the drive pinion with the gear reduction unit.
14. Install the drive pinion housing.
15. Push the shift lever guide into the drive pinion housing.
16. Install the shift lever plunger to the solenoid housing.




17. Push the shift lever sealing plate (1) into the housing.




18. Install the commutator end shield washers.
19. Install the commutator end shield bolts (2) to the starter motor.

Tighten
Tighten the bolts to 5 N.m (44 lb in).




20. Install the solenoid.
21. Install the solenoid screws.

Tighten
Tighten the screws to 5 N.m (44 lb in).

22. Install the solenoid field lead.
23. Install the lead nut (2).

Tighten
Tighten the nut to 8 N.m (71 lb in).

24. Install the starter motor.