Assembly Procedure

1. Install the field coils (1) in the armature frame:
^ Use a soft drift in order to seat the field coils in the armature frame.
^ Install the retainer.




2. Install the gear reduction unit shield to the armature frame.




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




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




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




9. Install the armature E clip (3).
10. Install the commutator end frame cover (1).

NOTE: Refer to Fastener Notice in Cautions and Notices.

11. Install the commutator end frame cover screws (2).

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




12. Install the armature with the brush holder, lightly tap the brush holder (1) in order to seat in the armature frame.




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




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




18. Install the commutator end washers.
19. Install the commutator end 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 field coil lead to the solenoid.
23. Install the field coil lead nut (2).

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

24. Bench test the starter operation.