Disassembly and Assembly

DISASSEMBLY
1. Remove positive brush connector from starter solenoid M-terminal.
2. Remove starter solenoid retaining screws and starter solenoid.
3. Remove through-bolts and separate drive end housing from starter frame and magnet. Remove seal from drive end housing. Remove starter drive and gear assembly from drive end housing.
4. Remove drive lever and pin from starter drive.
5. Remove starter drive stop ring and stop ring retainer from output shaft; then remove starter drive from output shaft.
6. Push E-ring off output shaft and separate gear assembly from output shaft.
7. Remove brush plate screws and brush end plate and bushing from starter frame and magnet.
8. Remove brush holder and push starter motor armature out of starter frame and magnet.

ASSEMBLY
1. Install starter motor armature in starter frame and magnet. Apply a thin coating of Syncolube (PTFE) Low Temperature Grease or equivalent meeting Ford specification WSG-M1C216-B2 on both ends of armature shaft and spline. Install brush holder while making sure brushes fit over commutator. Apply grease to bushing bore in brush end plate and bushing. Push back grommet onto starter frame and magnet and attach brush end with brush plate bolts. Tighten to 2-3 N.m (18-26 lb-in).

NOTE: Sealer material meeting Dow Formulation Silastic 737 or GE Silicone RTV 123 or equivalent meeting Ford specification ESA-M4G294-A should be replaced on starter motor during reassembly.

2. Apply grease to output shaft spline and place stationary gear over output shaft. Install armature thrust washer and push E-ring onto output shaft. Place starter drive onto output shaft and install starter drive stop ring and stop ring retainer. Attach drive lever to starter drive.
3. Grease and install planet gears.
4. Apply grease into drive end housing bushing bore (approximately one-quarter full). Install starter drive gear assembly into housing, making sure to line up bolt holes in gear assembly and housing. Place planet gear retainer over gear assembly. Install housing seal into drive end housing.
5. Position starter frame and magnet to housing and install through-bolts. Tighten to 5-10 N.m (45-88 lb-in).
6. Position starter solenoid to housing making sure that solenoid plunger is attached through drive lever (bottom starter solenoid M-terminal should have a metal strip attached to it). Tighten starter solenoid screws to 5-10 N.m (45-88 lb-in).
7. Attach positive brush connector to starter solenoid (bottom terminal). Tighten nut to 9-14 N.m (80-123 lb-in).
8. Check that starter motor no-load current draw is within specification.