Starter - Mitsubishi Ford Econoline E350

DESCRIPTION

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

The starter used on the 7.3L diesel engine uses permanent magnet fields, internal gear reduction and an externally mounted solenoid. System consists of a starter (ignition) switch, starter relay, batteries and wiring. (Scheme 5)

Scheme 5

PINION GAP

1. Secure starter in vise. Connect a switch in series with starter solenoid and battery. Connect second switch in series with starter field wire. (Scheme 6)
2. Turn both switches on. Starter drive should extend and motor should run. Turn switch No. 2 off. Starter should stop running, but drive pinion should remain extended. With the drive pinion extended, measure gap between pinion and stop ring.
3. Pinion gap should be.004-.079" (.10-2.0 mm). (Scheme 7) If adjustment is required, insert or remove shims between solenoid and drive end housing. Add shims to decrease gap and remove shims to increase gap.

Scheme 6

Scheme 7

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

ON-VEHICLE TESTING

STARTER MOTOR TEST

1. Ensure batteries are fully charged and in good condition. Ensure battery cables and connections are in good condition. Measure voltage at starter solenoid battery cable terminal. If voltage is battery voltage, go to step 2). If voltage is less than 12 volts, recheck battery cables and connections. Service as necessary.
2. Connect one lead of remote starter switch to starter solenoid battery cable terminal. Connect other lead to "S" terminal on starter solenoid. Operate remote starter switch. If engine does not crank, repair or replace starter. If engine cranks normally, starter is okay; go to STARTER RELAY TEST. If engine cranks sluggishly, recheck batteries, cables and connections. Repair or replace starter if batteries, cables and connections are okay.

STARTER RELAY TEST

Note. Perform STARTER MOTOR TEST before performing STARTER RELAY TEST.

1. Disconnect wire from terminal "S" of starter relay. Connect remote starter switch between terminal "S" and positive battery terminal. Ensure transmission is in Park on A/T models, or in Neutral on M/T models.
2. Attempt to crank engine with remote starter switch. If engine cranks, relay is okay. Check ignition switch, neutral or clutch switch, and circuitry for open or loose connections. If engine does not crank, replace relay.

SOLENOID TEST

With all solenoid wiring disconnected, check for continuity between terminals. See SOLENOID SPECIFICATIONS table. Check contact plate for excessive pitting. Repair or replace as necessary.

SOLENOID SPECIFICATIONS

BENCH TESTING

NO-LOAD TEST

1. Secure starter in vise. Ensure pinion gap is correct. See «ADJUSTMENTS»(/ford/econoline-e350/1985-1999/remont/starter/#starter-mitsubishi). Connect jumper lead between battery positive post and solenoid terminal "B". Connect remote start switch between battery positive post and solenoid terminal "S". (Scheme 8)
2. Starter should rotate at a smooth, consistent speed. If rotation is not smooth, ensure shim adjustment for armature-to-starter housing clearance is correct. If shim adjustment is okay, replace starter.

Scheme 8

ARMATURE OPEN CIRCUIT TEST

An open armature circuit can be often detected by inspecting the commutator for evidence of burning. If burning is present, replace armature. Check for damage to other related components.

ARMATURE GROUNDED CIRCUIT TEST

Connect voltmeter leads to negative battery terminal and starter commutator. Connect jumper cable to positive battery terminals and armature. (Scheme 9) If meter indicates any voltage, windings are grounded.

Scheme 9

OVERHAUL

Disassembly

1. Remove connector from "M" terminal. Remove solenoid retaining screws and solenoid. Remove starter housing through bolts. Separate housing from frame. (Scheme 10)
2. Remove armature, brush holder screws and end plate. Lift brush springs to remove brushes. Remove brush plate. Remove seal, holder and spacer. Remove inner gear housing and gear/shaft assembly.
3. Remove drive assembly by placing a pipe over end of shaft and tapping pipe to loosen retaining ring to expose retaining clip. Remove retaining clip, ring and drive assembly.

Scheme 10

Inspection

Check armature winding for separated or burned insulation. Check for open or shorted circuits. (Scheme 9) Check armature shaft and bearings for scoring or excessive wear. Check commutator for excessive runout. Machine commutator if runout exceeds.005" (.12 mm).

Reassembly

To reassemble, reverse disassembly procedure. Lubricate all sliding/pivot points with Multemp MS #2. Adjust shaft end play to .001-.020" (.02-.05 mm) gap between inner gear housing and outer gear housing. Add or remove shim(s) as necessary. Ensure pinion gap is okay. See PINION GAP under ADJUSTMENTS.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• ADJUSTMENTS
• PINION GAP