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Home >> Mercury >> 1989 >> Cougar/XR7 V6-232 3.8L SC >> Repair and Diagnosis >> Starting and Charging >> Starting System >> Starter Motor >> Technical Service Bulletins >> Starter Motor - Service Manual Supplemental Information >> Disassembly and Assembly

Disassembly and Assembly





28-07-6 Starter Motor-Gear Reduced Permanent Magnet

DISASSEMBLY AND ASSEMBLY

28-07-7 Starter Motor-Gear Reduced Permanent Magnet

DISASSEMBLY AND ASSEMBLY (Continued)

Disassembly

1. Remove positive brush connector from solenoid motor (M) terminal.

2. Remove solenoid attaching screws and solenoid. Remove housing seal and lever support from drive end housing.

3. Remove through-bolts and separate drive end housing from motor frame. Remove drive and gear assembly from drive end housing.


4. Remove drive lever from drive assembly. Remove stop ring and retainer from driveshaft, then remove drive assembly from shaft. Push E-ring off driveshaft, and separate gear assembly from driveshaft.

5. Remove brush plate screws and brush end plate from motor frame. Remove brush assembly and push armature out of frame.




Cleaning and Inspection

CAUTION: Do not wash the drive because the solvent will wash out the lubricant causing drive to slip. Use a brush or compressed air to clean the drive, armature, brush, and gear assemblies, drive end housing, pole pieces and planet gears. Wash all other parts in solvent and dry.

1. Inspect armature windings for broken or burned insulation and unwelded or open connections.

2. Check armature for open circuits, shorts and grounds.

3. Check commutator for runout. Inspect armature shaft and two bearings for scoring and excessive wear with Dial Indicator Tool - 4201-C or equivalent. If commutator is rough, or more than 0.12 mm (.005 inch) out of round, turn it down to specification or replace.




4. Examine gears, spline on driveshaft, and drive pinion for chipped, broken or worn conditions. Replace if required.

28-07-8 Starter Motor-Gear Reduced Permanent Magnet

DISASSEMBLY AND ASSEMBLY (Continued)

Assembly

1. Install armature assembly in starter frame. Apply a thin coating of ESF-MIC218-A Grease or equivalent low temperature grease on both ends of armature shaft and spline. Install brush assembly ensuring brushes fit over commutator. Apply grease to bearing bore in brush end plate. Push back grommet onto frame and attach brush end with brush plate screws. Tighten to 2.3-3.4 N-m (20-30 in.lbs.).

2. Apply grease to driveshaft spline and place stationary gear assembly over driveshaft. Install armature thrust washer and push E-ring onto driveshaft. Place drive assembly onto shaft and install stop ring and retainer. Attach drive lever to drive assembly.

3. Grease and install planet gears.

4. Apply grease into drive end housing bearing bore (approximately one-quarter full). Install drive gear assembly into housing, making sure to line up bolt holes in gear assembly and housing. Place gear cover over gear assembly.

5. Position starter frame to housing and install through-bolts. Tighten to 5.1-6.1 N-m (45-54 in.lbs.).

6. Install lever support and housing seal in drive end housing. Correctly position solenoid to housing ensuring that solenoid plunger is attached through drive lever (bottom solenoid terminal (M) should have a metal strip attached to it). Tighten solenoid bolts to 5.1-9.6 N-m (45- 85 in.lbs.).

7. Attach positive brush connector to solenoid (bottom terminal).

8. Check that starter no-load current draw is within specification. Refer to Bench Tests.


Starter Drive Replacement

1. Remove solenoid, lever support and housing seal.

2. Remove through-bolts and separate motor assembly drive end housing. Remove drive gear assembly from housing and detach drive lever.

3. Remove stop ring and retainer from driveshaft and then remove drive assembly.

4. Apply a thin coating of ESF-MIC218-A Grease or equivalent low temperature grease on driveshaft spline. Install new drive gear assembly on driveshaft. Install new stop ring and retainer. Attach drive lever.

5. Partially fill drive end housing bearing bore with grease (approximately one-quarter full). Install drive gear assembly in housing making sure to line up boltholes in gear assembly and housing.

6. Position starter frame to housing and install through-bolts. Tighten to 5.1-6.1 N-m (45-54 in.lbs.).

7. Install lever support and housing seal in drive end housing.

8. Install solenoid. Refer to Assembly.


Armature Replacement

1. Remove solenoid, lever support and housing seal.

2. Remove through-bolts and separate motor from drive end housing.

3. Remove brush end plate screws, brush end plate and brush assembly from starter frame. Remove armature from frame.

4. Install new armature in frame. Apply a thin coating of ESF-MIC218-A Grease or equivalent low temperature grease on both ends of armature shaft and spline.

5. Install brush assembly. Ensure that brushes fit over commutator. Push black grommet onto frame. Apply grease to bearing bore in brush end plate and attach to starter frame.

6. Partially fill drive end housing bearing bore with grease (approximately one-quarter full). Position starter frame to housing and install through-bolts. Tighten to 5.1-6.1 N-m (45-54 in.lbs.).

7. Install lever support and housing seal in drive end housing.

8. Install solenoid. Refer to Assembly.

9. Check that starter no-load current draw is within specification. Refer to Bench Testing.
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