Starter Motor Overhaul (SD-260 Drive-End Frame Assem)

Replacing The Pinion Stop Collar:

1. Wipe the armature shaft clean.
2. Lubricate the area that will be under the drive assembly. Use lubricant GM P/N 1960954 or equivalent.
3. Wipe the drive assembly clean
4. Assemble the drive assembly onto the armature shaft.
5. Assemble the pinion stop collar with the flat side of the collar toward the drive pinion.
6. Assemble the new retaining ring onto the armature shaft. Slide the ring down the shaft until it seats in the shaft grove.






7. Assemble the thrust collar onto the shaft with the small flange toward the retaining ring. Using two sets of pliers, push the pinion stop collar and the thrust collar together to snap the stop collar onto the retaining ring
8. Inspect the drive end bearing. If no lubrication is visible, replace the bearing using a suitable driver and hammer. Do not lubricate the bearing.
9. Assemble the new drive end bearing by pressing it until it is recessed 1.6 mm (0.06 in) into the casing. It is prelubricated. Do not add lubricant.
10. Assemble the shift lever to the drive assembly by spreading the arms slightly to snap it onto the buttons on the drive collar.

Armature, Drive And Shift Lever Assembly:

11. Assemble the plunger to the lever by snapping it into place. Note which side of the lever is up.
12. Assemble the armature shaft into the drive end bearing while sliding the shift lever retainer into the slot on the drive end housing.
13. Assemble the spring onto the plunger.
14. Assemble the plug.
15. Assemble the solenoid and clamp onto the drive end frame, aligning the M terminal with the field connector.

NOTICE: Refer to Fastener Notice in Cautions and Notices.

16. Assemble the solenoid clamp retaining screws.

Tighten
Tighten the solenoid clamp retaining screws to 11 N.m (95 lb in).