OVERHAUL
Check commutator for out-of-round and proper amount of undercut. Replace or repair armature if not within specification. See the STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear line (outer line closest to commutator contact surface). Check pinion gap. See PINION GAP CHECK in this article.
DISASSEMBLY
Note. Procedures may vary slightly between conventional and reduction gear starters.
- Loosen nut securing connecting plate-to-magnetic switch "M" terminal. Remove screws securing magnetic switch and remove switch (solenoid) assembly. Remove through bolts and brush cover assembly. Tap yoke assembly loose with wooden mallet. Remove yoke, armature assembly and pinion shift lever.
- Remove pinion stop ring from end of armature shaft by pushing stop ring to clutch side. Remove snap ring and overrunning clutch assembly from armature shaft.
Overrunning Clutch Assembly
- Inspect pinion assembly and sleeve. Sleeve should slide freely on armature shaft and spline. If damage or resistance is noted, replace assembly.
- Check pinion and flywheel teeth for excessive rubbing or damaged teeth. Replace as required.
REASSEMBLY
To reassemble, reverse disassembly procedure. Fill gear case on reduction gear models with grease. Lightly oil pinion and all bearing surfaces.
Scheme 3
Scheme 4
| Application | In. (mm) | ||
|---|---|---|---|
| Commutator Maximum Runout | .004 (.10) | ||
| Commutator Minimum Diameter | |||
| Colt, Colt 200 & Summit | 1.220 (30.99) | ||
| Colt Vista & Summit Wagon | |||
| A/T | 1.134 (28.80) | ||
| M/T | 1.220 (30.99) | ||
| Ram-50 | |||
| 2.4L A/T & 3.0L | 1.134 (28.80) | ||
| 2.4L M/T | 1.236 (31.39) | ||
| Stealth | 1.118 (28.40) | ||
| Commutator Undercut Depth | .020 (.51) | ||
| Pinion Gap | 020-.079 (.51-2.01) | ||
STARTER SPECIFICATIONS
| Model/Application | Starter Type (1) | Test Voltage | Maximum Amps @Minimum RPM | ||
|---|---|---|---|---|---|
| Colt, Colt 200 & Summit | |||||
| A/T | DD | 11.5 | 60 @ 6600 | ||
| M/T | DD | 11.5 | 60 @ 6500 | ||
| Colt Vista & Summit Wagon | |||||
| 1.8L | |||||
| A/T | GR | 11 | 90 @ 3000 | ||
| M/T | DD | 11.5 | 53 @ 6000 | ||
| 2.4L | |||||
| A/T | GR | 11 | 90 @ 3000 | ||
| M/T | DD | 11.5 | 60 @ 6600 | ||
| Ram-50 | |||||
| 2.4L A/T & 3.0L | GR | 11 | 90 @ 3000 | ||
| 2.4L M/T | DD | 11.5 | 60 @ 6600 | ||
| Stealth | GR | 11 | 90 @ 3000 | ||
| (1) The letters DD indicates direct drive and GR indicates gear reduction. | |||||
| (1) | The letters DD indicates direct drive and GR indicates gear reduction. |
STARTER NO LOAD SPECIFICATIONS