Removal & Installation
- Disconnect negative battery cable and then disconnect positive battery cable. Remove nuts from battery rods that fasten battery hold-down bar clamp. Check battery carrier tray for obvious cracks or damage. Unclip lead to negative battery cable from side of battery tray, if applicable. Detach carrier tray, if necessary, by removing upper battery carrier tray bolts, and side bolt that connects hydraulic clutch hose bracket to battery carrier tray, if applicable, as shown. Remove lower battery tray bolts.
- Install battery carrier by fastening carrier tray upper, lower, and side bolts. Tighten battery carrier tray upper, lower, and side bolts, if applicable, to 20 N.m (15 ft. lbs.). Push in clip of negative battery lead to hole in side of battery tray, if applicable. Install battery into tray.
- Fasten bar clamp to battery by loosely attaching battery rods from battery tray cutouts through bar clamp holes, and loosely tightening nuts. Tighten battery retainer clamp-to-battery rod nuts to 5 N.m (44 INCH Lbs.). Connect negative and positive battery cables. Tighten battery cable nuts to 15 N.m (11 ft. lbs.).
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Scheme 8
Scheme 9
Scheme 10
- Remove starter. Remove starter through-bolts. Remove commutator end frame/brush holder assembly. Inspect brushes, pop-out springs, and brush holders for wear and damage. (Scheme 4) Replace assembly, if necessary. NOTE: This test should be made for each ground or insulated brush to ensure continuity through both brushes and leads. If lamp fails to light, field coil is open and will require replacement.
- Use the following procedure for only those starters having a shunt coil connection: Using a test lamp, place one lead on shunt coil terminal and connect other lead to a ground brush or insulated brush. (Scheme 5) When testing series coils for ground, separate series and shunt coil strap terminals during test. (Scheme 6) Make sure strap terminals are not touching case or other ground. Using a test lamp, place one lead on grounded brush holder and other lead on either insulated brush. If lamp is lit, a grounded series coil is indicated and must be repaired or replaced. To test for an open circuit, on each insulated brush, place one lead on series coil terminal and other lead on insulated brush. If test lamp is not lit, series coil is open and will require repair or replacement. NOTE: Complete testing in a minimum amount of time to prevent overheating of solenoid. If specified current draw does not include solenoid, deduct from armature reading specified current draw of solenoid hold-in winding.
- Check armature to see if it turns freely. If armature does not turn freely, break down assembly immediately. Otherwise, give armature a no-load test. To begin no-load test, close switch and compare rpm, current, and voltage readings with specifications. Make disconnections only with switch open. (Scheme 7) Use test results as follows: Rated current draw and no-load speed indicate a normal condition for starter motor. Low free speed and high current draw indicate too much friction (tight, dirty or worn bearings or a bent armature shaft), a shorted armature, or a shorted armature or fields. Failure to operate with high current draw indicates a direct ground in terminal or fields, or "frozen" bearings. Failure to operate with no current draw indicates an open field circuit, open armature coils, broken brush springs, worn brushes, high insulation between commutator bars, or other causes which would prevent good contact between brushes and commutator. Low, no-load speed and a low current indicate high internal resistance and high current draw, which usually mean shorted fields.
- Remove solenoid assembly screws. Remove field connector nut. Disconnect field connector. (Scheme 8) Rotate solenoid 90 degrees and remove it along with plunger return spring. Slide field frame with enclosed armature assembly away from starter assembly. Remove shield. Separate field frame from armature. Inspect shaft, bearing, and pinion for discoloration, damage, or wear. Replace if necessary.
- Inspect points where armature conductors join commutator bars. Make sure they have a good connection. A burned commutator bar is usually evidence of a poor connection. If test equipment is available, check armature for short circuits by placing it on a growler, and holding a hacksaw blade over armature core while armature is rotated. If hacksaw blade vibrates, replace armature. Recheck after cleaning between commutator bars. If hacksaw blade vibrates, replace armature.
- Remove gears, bushing, and washer. Remove cushion and driveshaft assembly from starter housing. (Scheme 9) Disassemble driveshaft assembly by first separating needle bearing from driveshaft. Remove collar and locking ring from groove in driveshaft. (Scheme 10) Remove pinion stop and drive from driveshaft. (Scheme 11) Remove gear support from driveshaft. (Scheme 12) If not done in previous steps, remove screws that hold solenoid assembly into housing, and remove nut from field coil connector.
- Rotate solenoid 90 degrees and remove it along with return spring. Remove plunger with boot and shift lever assembly. (Scheme 13) When starter motor is disassembled and solenoid is replaced, check pinion clearance. Disconnect motor field coil connector from solenoid motor terminal and carefully insulate connector. Connect one 12-volt battery lead to solenoid switch terminal and other 12-volt battery lead to starter frame. NOTE: The pinion clearance must be correct to prevent buttons on shift lever yoke from rubbing on clutch collar during engine cranking.
- Flash a jumper lead momentarily from solenoid motor terminal to starter frame, allowing shifting of pinion in cranking position, where it will remain until battery is disconnected. Push pinion back as far as possible to take up any movement, and check clearance with a feeler gauge. (Scheme 14) The clearance should be.25 to 3.56 mm (.01-.14"). NOTE: A means for adjusting pinion clearance is not provided on starter motor. If clearance does not fall within limits, check for improper installation and replace all of worn parts.
