Starter - Delco-Remy Ford Cab & Chassis Ranger

DESCRIPTION

Starter is a 12-volt, 4-pole unit of conventional design and has a solenoid pinion shaft (overrunning clutch) with entire mechanism enclosed within housing. Field assembly consists of 4 series coils or combination of series coils with 1 more shunt coil. Brush assemblies are completely enclosed within field frame at commutator end so entire starter and drive assembly is protected.

Starter solenoid is flange mounted on drive end housing and has a compression-type return spring located inside solenoid case. Ford models use the 27MT starter, which uses a center bearing.

SOLENOID WINDING TESTS

Tests are performed with all leads disconnected from solenoid. Complete tests in minimum amount of time to prevent solenoid from overheating.

Hold-In Winding (All Models)

1. Connect an ammeter, voltmeter, carbon pile and battery into starter circuit. (Scheme 7) Using carbon pile, decrease battery voltage to 9 volts for Ford models.
2. Ammeter should read 12-16 amps for Ford. Higher readings indicates winding is shorted or grounded. Lower reading indicates excessive resistance.

Both Windings in Parallel (GM Only)

Using same connections as hold-in winding test, ground "M" terminal and using carbon pile adjust voltage to 10 volts. Amperage draw should be 41-47 amps.

Pull-In Windings

Note. Use carbon pile between battery and "M" terminal if its required to reduce voltage to specified testing voltage. If not, connect jumper directly from battery to "M" terminal.

Using solenoid test connections in dashed lines, decrease battery voltage to 9 volts. (Scheme 7) Pull-in winding amperage draw should be 43-54 amps.

Connections for Testing Solenoid Windings Connections shown in dashed lines are used only for pull-in winding testing. Scheme 7

STARTER NO LOAD TEST

1. To perform test, connect a tachometer, ammeter and voltmeter into start circuit. (Scheme 8) Adjust carbon pile to specified voltage indicated in table.
2. Read current draw and armature speed to ensure they are within specifications. Do not apply voltage greater than specified, as excessive voltage may cause armature to throw windings due to excessive speed.
3. Low free speed and high current draw indicates too much friction, shorted armature, or grounded armature or fields. Failure to operate with high current draw indicates a direct ground in terminal or fields or frozen bearings.
4. Failure to operate with no current draw indicates an open field, open armature coils, or broken brush springs, worn brushes, or high commutator insulation.
5. If no-load speed is low and there is low current draw, suspect high internal resistance due to poor connection, defective leads, or dirty commutator. A high free speed and high current draw usually indicates shorted fields.

Connections for No Load Test Use fully charged battery to make proper test. Scheme 8

STARTER NO-LOAD SPECIFICATIONS (1)

DISASSEMBLY

1. Disconnect field coil connector from solenoid motor terminal. Remove solenoid mounting screws and rotate solenoid 90° and remove along with solenoid plunger spring.
2. Remove 2 through bolts, commutator end frame, field frame assembly and washer.
3. Remove shift lever pivot bolt, center bearing screws and drive gear housing from armature shaft. Shift lever and plunger assembly will now fall away from starter clutch.
4. Slide a 5/8" deep socket over pinion shaft and with a hammer, strike socket against retainer to drive retainer off snap ring. Remove snap ring from groove in armature shaft.
5. Remove retainer, clutch assembly, fiber washer and center bearing. Remove roll pin and remove shift lever and plunger.

CLEANING

Clean all parts by wiping with clean cloth. Do not clean armature, field coils, or drive assembly in any type of grease dissolving solvent as this will damage insulation and wash lubricant out of drive assembly.

Armature

Test armature for shorted coils with a growler. Check for grounded coils using a self-powered test light. Place one test lead on armature core or shaft, and other test lead on commutator. Lamp should not light. If lamp lights, armature is grounded and should be replaced.

Field Coils

1. Using self-powered test light, place one test lead on field coil terminal strap, touch other test lead to field coil brush lead (check series coils and shunt coils separately at appropriate terminals).
2. Lamp should light. If lamp does not light, coils are open. Check for grounds by placing one test lead on field armature strap, touch other lead to armature core or shaft. If lamp lights, 1 or more coils are grounded.

Replace brushes if worn to 1/2 of original length, or if oil-soaked or pitted. Check brush spring tension and replace springs if weak or distorted. Deformed or bent brush holders can be replaced by service units which are installed with screws and nuts.

Drive & Pinion

Pinion should turn freely in overrun direction and should not slip in drive direction. Check spring for correct tension and drive collar for wear (these parts can be removed for replacement by forcing collar toward clutch and removing lock ring from end of tube). Replace drive assembly if pinion teeth are worn, chipped, or cracked.

All Models (Except 5MT Starter) Brush Holder and Assembly Replace brushes if worn to half of original length. Scheme 9

Pinion Clearance

1. Disconnect motor field coil connector and insulate it carefully. Connect a battery from solenoid switch terminal to solenoid frame. Momentarily flash a jumper lead from motor terminal to solenoid frame.
2. This shifts pinion into cranking position. Push pinion back toward commutator end to eliminate slack. Measure distance between pinion and pinion stop. When installing starter, check clearance between pinion and flywheel ring gear teeth.
3. Insert gauge .020" (.6 mm) diameter wire, about 3" (76 mm) long, with a 1/4" to 1/2" 90° bend in end between pinion tooth and ring gear. Center pinion tooth between flywheel teeth when making measurement.

PINION CLEARANCE

Scheme 10

1. On diesel model starters, assemble armature and clutch as follows: Lubricate drive end of armature shaft with silicone lubricant and install center bearing, fiber washer and clutch assembly onto armature, with pinion away from armature. Slide retainer onto shaft and install snap ring and thrust washer. see scheme 4: Checking Pinion-to-Housing Clearance Force gear rearward to eliminate slack.
2. Position retainer and thrust washer with snap ring in between. Using pliers, grip retainer and washer and squeeze until snap ring is forced into retainer and is held in groove in armature shaft.
3. On all models, lubricate drive gear housing bushing with silicone lubricant. Engage shift lever yoke with clutch and slide complete assembly into drive gear housing. (Scheme 10): Exploded View of Delco-Remy 27MT Starter Assembly 5MT & 10MT starters similar except they have no center bearing.
4. Install center bearing screws and shift lever pivot bolt. Tighten securely. Install solenoid assembly on drive gear housing. Apply sealer (No. 1050026) to solenoid flange where it meets drive housing and field frame, using care not to damage brushes.
5. Position field frame against drive gear housing on alignment pin using care not to damage brushes. Lubricate commutator end frame bushing with silicone lubricant. Install washer on armature shaft and slide end frame onto shaft and install through bolts.
6. On diesel models, install insulator and then end frame onto shaft. Install through bolts, making sure they pass through bolt holes in insulator. Connect field coil connector to solenoid terminal. Check pinion clearance as outlined under, OVERHAUL and TESTING.

Exploded View of Shift Lever Assembly. Scheme 11