Disassembly and Reassembly

Starter:

Disassembly
1. Remove nut from M terminal.
2. Remove field wire from M terminal.






NOTE: If pinion depth shims are found between solenoid and drive end housing, remove them and set aside.




3. Remove solenoid screws and magnetic switch.




4. Remove solenoid plunger spring.




5. Disengage plunger from lever and remove plunger.




6. Remove bolts from rear cover. Separate motor assembly from drive end housing. Also separate motor assembly from planetary gear set, if present.




7. Remove lever from drive pinion.




8. Drive stopper from snap ring using a deep well socket or similar tool.




9. Remove snap ring from its groove in pinion shaft.
10. Remove stopper and drive pinion from pinion shaft.

11. Remove two brush plate screws and rear cover.
12. Remove armature from field coil housing.




13. Remove armature washers from the end of the armature.


Reassembly
1. Reassemble armature washers to the end of armature.
2. Reassemble armature in field coil housing.




3. Reassemble rear cover and tighten two brush plate screws.

Tightening torque: 1.7 - 3.2 lb-ft (2.4 - 4.4 N.m, 0.24 - 0.44 kg-m)

4. Reassemble drive pinion and stopper on pinion shaft.




5. Place snap ring on its groove in pinion shaft.




6. Reassemble stopper.




7. Reassemble lever on drive pinion.




8. If present, reassemble planetary gear set to motor assembly.
9. Reassemble motor assembly in drive end housing.
10. Place bolts in rear cover and tighten.

Tightening torque: 2.8 - 5.2 lb-ft (3.8 - 7.1 N.m, 0.39 - 0.72 kg-m)




11. Engage plunger in lever.




12. Insert solenoid plunger spring.
13. Reassemble magnetic switch and tighten solenoid screws.

Tightening torque: 3.0 - 5.6 lb-ft (4.17.6 N.m, 0.42-0.77 kg-m)

14. Apply battery power to the S terminal and ground starter motor body. Pinion will eject outward and then stop.
15. Measure clearance (pinion gap) between pinion and stopper.

Pinion gap: 0.020 - 0.079 in (0.5 - 2.0 mm)






NOTE: Be careful not to let electricity flow continuously for more than 10 seconds.

16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers used between solenoid and drive housing. The gap will become smaller if the number of washers is increased.






NOTE: Do not use more washers than plates.

17. Connect field wire to M terminal.