Disassembly and Assembly

DISASSEMBLY





1. Remove the (A) starter solenoid M-terminal nut and the (B) starter motor brush holder cable.





2. Remove the two (A) solenoid bolts and the (B) starter solenoid.





3. Remove the two (A) through-bolts, the (B) brush end plate and bushing and the (C) brush holder.





4. Remove the two (A) brush plate bolts and separate the (B) brush holder from the (C) brush end plate and bushing.





5. Remove the four (A) brush springs from the (B) brush holder and then remove the (C) brush set and the (D) bushing.

NOTE: Brushes must be marked for position before removal.





6. Pull the starter motor armature out of the starter frame and magnet.





7. Remove the starter drive and lever.
1 Remove the stop ring retainer.
2 Remove the starter drive stop ring.
3 Remove the starter drive and lever.





8. Remove the drive lever and pin from the starter drive.





9. Remove the (A) E-ring and the (B) pinion thrust washer from the (C) output shaft.





10. Separate the (A) stationary gear from the (B) output shaft.





11. Separate the (A) output shaft from the (B) starter motor armature. and remove the (C) armature. thrust ball.

CAUTION: Use caution not to lose the armature thrust ball.





12. Remove the (A) planet gear retainer and the three (B) planet gears from the (C) output shaft.





13. Remove the bushing.





14. Clean the starter motor parts
1 Use only a brush or dry cloth to clean damageable parts.
2 Solvent can be used to clean other parts.

CAUTION: Cleaning solvent can damage certain starter motor parts.

ASSEMBLY





1. Soak the two (A) bushings for 20 minutes in 20W engine oil and then install them in the (B) brush end plate and the (C) starter drive.





2. Lubricate and install the starter motor armature.
1 Lubricate the starter motor armature.
- Use Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-13.
2. Install the starter motor armature.





3. Install the (A) brush set and the four (B) brush springs in the (C) brush holder.





4. Install the (A) brush holder into the (B) starter frame and magnet.

NOTE: Make sure the brushes are on top of the commutator.





5. Lubricate and install the brush end plate and bushing.
1 Lubricate the brush end plate bushing.
- Use Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.
2. Position the (A) brush end plate and bushing and install the two (B) brush plate bolts.





6. Lubricate the output shaft spline and install the stationary gear.
1 Lubricate the output shaft spline.
- Use Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.
2. Install the (A) stationary gear, the (B) pinion thrust washer and the (C) E-ring on the (D) output shaft.





7. Install the (A) starter drive on the (B) output shaft and then install the (C) starter drive stop ring and the (D) stop ring retainer.





8. Connect the (A) drive lever and pin to the (B) starter drive.





9. Lubricate and install the (A) planet gears on the (B) output shaft and install the (C) planet gear retainer and the (D) armature thrust ball.
- Use Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.





10. Lubricate and install the starter drive assembly.
1 Lubricate the starter drive bore.
- Use Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.
2 Install the starter drive assembly.
3 Install the seal.





11. Position the (A) starter frame assembly on the (B) drive end housing and install the two (C) through-bolts.





12. Position the (A) starter solenoid on the (B) starter motor and install the two (C) solenoid bolts.





13. Position the (A) starter motor brush holder cable on the (B) starter solenoid M-terminal and install the (C) starter solenoid M-terminal nut.