Starter Drive/Bendix: Service and Repair

1. Remove positive brush connector from starter solenoid M-terminal. Remove starter solenoid retaining screws and remove starter solenoid.
2. Remove through-bolts and separate motor assembly from drive end housing. Remove housing seal from drive end housing. Remove starter drive gear assembly from housing and detach drive lever and pin.
3. Remove starter drive stop ring and stop ring retainer from output shaft. Remove starter drive assembly.
4. Apply a thin coating of Teflon (R) Lube E7FZ-19590-A or equivalent meeting Ford specification ESB-M1C111-A on output shaft spline. Install new starter drive gear assembly on output shaft. Install new starter drive stop ring and stop ring retainer. Attach drive lever.
5. Partially fill drive end housing bushing bore with grease (approximately one-quarter full). Install starter drive gear assembly in housing. Make sure to line up bolt holes in starter drive gear assembly and housing.
6. Install lever support and housing seal in drive end housing.
7. Position starter frame and magnet to housing and install through-bolts. Tighten to 5-10 N.m (44-88 Lb-In).
8. Install starter solenoid.