Disassembly and Assembly

DISASSEMBLY







1. Remove the positive brush connector nut from the starter solenoid M-terminal.







2. Remove the starter solenoid.







3. Remove the two through bolts and separate the drive end housing from the starter frame.







4. Remove the output shaft.

NOTE: An armature thrust ball is located between the end of the starter motor armature shaft and the seat provided in the output shaft. Retain this part for reassembly.







5. Remove the starter drive stop ring from the output shaft.







6. Remove the starter drive from the output shaft.







7. Remove the drive lever and pin from the starter drive.
1. Remove the clip.
2. Remove the drive lever and pin from the starter drive.







8. Remove the armature thrust washer.
1. Remove the Truarc C-ring.
2. Remove the washer.







9. Remove the planet gear retainer.







10. Separate the output shaft from the stationary gear.







11. Remove the brush end plate and bushing.
1. Remove the bolts.
2. Remove the brush end plate and bushing.







12. Remove the starter motor armature from the starter frame.
1. Remove the brush holder.
2. Remove the armature from the frame.

ASSEMBLY







1. Remove the brush holder cover.

NOTE: Apply a thin coating of low-temperature grease meeting Ford specification WSG-MIC218-B2 on both ends of the armature shaft and splines.







2. Remove the springs.







3. Install the brush holder on the armature.
1. Position the brush holder on the armature.
2. Install the springs.







4. Install the brush holder cover.







5. Install the starter motor armature into the starter frame.

NOTE: Make sure the brush holder and armature do not separate.







6. Install the brush end plate and brushing.







7. Install the output shaft onto the stationary gear.







8. Install the planet gear retainer.







9. Install the armature thrust washer.







10. Connect the drive lever and pin to the starter drive.
1. Connect the drive lever and pin to the starter drive.
2. Install the clip.







11. Install the starter drive onto the output shaft.







12. Install the starter drive stop ring.







13. Install the drive end housing into the starter frame.







14. Install the starter solenoid.







15. Install the positive brush connector nut from the starter solenoid M-terminal.