Starter - Motorcraft Ford LTD Crown Victoria I

DESCRIPTION

The starting system includes a 4-pole, 4-brush starting motor with an integral positive engagement drive, a starter-ignition switch, neutral start switch (some auto. trans. models), starter relay, and circuit wiring.

Starter motor consists of both 4" and 4 1/2" diameter frames, a moveable pole shoe, and appropriate linkage to engage drive mechanism. Inside the drive assembly, an overrunning clutch prevents starter motor from being driven to excessive speed by the ring gear when the engine starts.

OPERATION

Turning the ignition switch to the "START" position activates the solenoid. The solenoid then connects the battery to the starter.

When the starter is not in use, one of the field coils is connected directly to ground through a set of contacts. When the starter is first connected to the battery, a large current flows through the grounded field coil, activating the moveable pole shoe.

The pole shoe, attached to the starter drive plunger lever, engages the drive assembly into the flywheel ring gear. When the moveable pole shoe is fully seated, it opens the field coil grounding contacts and the starter operates normally. A holding coil is used to maintain the moveable shoe in the fully-seated position while the starter is turning the engine.

ON-VEHICLE TEST INFORMATION

Note. Prior to performing tests, clean and connect battery cables. Ensure battery is fully charged. Remove coil high tension wire from distributor and ground it. Place transmission in Neutral or Park and apply parking brake. When making voltmeter connections, ensure leads are connected to battery posts or threaded terminals and not to cable ends.

STARTER CRANKING CIRCUIT TEST

1. Disconnect ignition coil secondary wire. Connect a remote control starter switch from positive battery terminal to "S" terminal of starter relay.
2. Connect a voltmeter and crank engine as described in each of the following situations. Connect negative voltmeter lead to starter terminal. Connect positive voltmeter lead to positive battery terminal. Voltage drop should not exceed 0.5 volts. Connect negative voltmeter lead to battery side of starter relay. Connect positive voltmeter lead to positive battery terminal. Voltage drop should not exceed 0.1 volts. Connect negative voltmeter lead to starter side of starter relay. Connect positive voltmeter lead to positive battery terminal. Voltage drop should not exceed 0.3 volts. Connect negative voltmeter lead to negative battery terminal. Connect positive lead of voltmeter to engine ground. Voltage drop should not exceed 0.3 volts.
3. If any test shows excessive voltage drop, inspect and repair wiring in the starter cranking circuit.

STARTER LOAD TEST

1. Connect test equipment. (Scheme 1) Ensure no current is flowing through ammeter and carbon pile rheostat. Disconnect "S" terminal push-on connector from starter relay.
2. Connect a remote control starter switch between "S" terminal and positive battery terminal. Crank engine and determine and note voltmeter reading. Stop cranking engine and reduce resistance of the rheostat until voltmeter indicates same reading as that obtained while cranking engine.
3. The ammeter will now indicate starter current draw under load. Normal starter load current is 150-250 amps for 4" starters and 150-210 amps for 4 1/2" starters. If load test current is not within specifications, repair or replace starter motor.

Scheme 1

STARTER NO-LOAD TEST

Note. The starter no-load test will determine such problems as open or shorted windings, rubbing armature, and a bent armature shaft.

1. Connect positive lead of load tester to positive terminal of a fully charged battery. Connect negative lead of tester to negative battery terminal. (Scheme 2)
2. Connect voltmeter leads of load tester to positive and negative battery terminals. Connect a jumper wire between negative battery terminal and starter frame. Connect another jumper wire between the positive battery terminal and positive terminal of starter motor. NOTE: Ensure no current is flowing through ammeter.
3. Turn rheostat to maximum counterclockwise position and note voltmeter reading. Disconnect jumper leads from starter motor. Reduce resistance of the rheostat until voltmeter reading is the same as when starter was running. Ammeter should read 80 amps for 4" starter and 85 amps for 4 1/2" starter.

Scheme 2

ARMATURE OPEN CIRCUIT TEST

An open armature circuit can be detected by inspecting the commutator for evidence of burning. A spot burned on the commutator is caused by an arc formed every time that segment of the commutator passes under a brush. If burning is detected, replace armature assembly and check for damage to other related components.

ARMATURE & FIELD GROUNDED CIRCUIT TEST

Note. This test will determine if field winding insulation has failed, permitting a conductor to contact the frame or armature core.

1. Connect negative voltmeter lead to negative battery terminal. Connect positive voltmeter lead to commutator. Connect a jumper wire between positive battery terminal and armature core. If any voltage is indicated, windings are grounded and armature should be replaced.
2. Connect a jumper wire between negative battery terminal and starter frame. Connect negative voltmeter lead to positive battery terminal. Connect positive voltmeter lead to field coil eyelet terminal. If any voltage is indicated, field windings are grounded and should be replaced.

REMOVAL & INSTALLATION

Disconnect battery ground cable. Raise vehicle and disconnect cable at starter terminal. Remove starter rear support bracket bolts and remove bracket. Remove cable support. To install, reverse removal procedure.

Note. Some vehicles are equipped with roll restrictor brace-to-starter studs located on transmission housing. Brace and attaching nuts must be removed.

DISASSEMBLY

1. Remove cover screw, cover, through bolts, starter drive end housing, and starter drive plunger lever return spring. Remove starter gear plunger lever pivot pin and lever. Slide armature out.
2. Remove stop ring retainer, thrust washer, and stop ring from armature shaft. Remove starter drive gear assembly. Remove brush end plate and insulator assembly. Remove brushes from plastic brush holder and lift out holder. Note location of brush holder with respect to end terminal.
3. Remove 2 copper rivets retaining ground brushes to frame. Bend up edges of the sleeve which is inserted in rectangular hole in frame, and remove sleeve and retainer. Detach shunt field coil ground wire from copper tab riveted to frame.
4. Remove the 3 pole shoe retaining screws with Polescrew Remover (10044-A) and an arbor press. Cut field coil connection at switch post lead. Remove pole shoes and coils from frame. Cut positive brush leads from field coils as close to the field connection point as possible.

CLEANING & INSPECTION

1. Clean field coils, armature, brush end plate, drive end housing and starter drive with compressed air. Wash other parts in solvent. Inspect armature for open circuits, shorts, grounds and broken or burned insulation. Check commutator for scoring or excessive wear.
2. If commutator is rough or more than .005" (.13 mm) out of round, service as necessary. Check brush holders for broken springs and insulated brush holders for shorts to ground. Tighten any loose rivets. Replace brushes if less than .25" (6.4 mm) in length.
3. Check field coils for burned or broken insulation and continuity. Replace as necessary. Examine wear pattern on starter drive teeth. Replace if pitted, or if broken teeth are found. Starter drive teeth must engage ring gear teeth more than 1/2 of tooth depth.

Scheme 3

1. Position coils and pole pieces (with coil leads in terminal screw slot) and install retaining screws. As screws are tightened, strike frame several times with soft-faced hammer to seat and align pole shoes. Stake screws after they are fully tightened.
2. Install plunger coil sleeve and retainer, and bend tabs to retain coils to frame. Position grommet on end terminal and align into notch in frame. Using a 300-watt soldering iron and rosin core solder, solder field coil to starter switch terminal post.
3. Check for continuity and grounds in assembled coils. Position the ground brushes to starter frame and rivet securely. Apply a thin coat of Lubriplate on armature shaft splines. Install starter motor drive gear assembly to armature shaft, new stop ring, stop ring retainer, and thrust washer.
4. Install armature in starter frame. Position starter drive gear plunger lever to frame and starter drive assembly. Install pivot pin. Fill drive end housing bearing 1/4 full with grease. Position drive end housing to frame making sure lever return spring engages tang on lever.
5. Install brush holder, brushes, and springs. Positive brush leads should be positioned in their respective slots to prevent potential grounding. Install brush end plate. Ensure that end plate insulator is positioned properly on end plate.
6. Install through bolts to starter frame and tighten to 55-80 INCH lbs. (6-9 N.m). Install starter drive plunger lever cover and tighten retaining screw. Check starter no-load current draw. It should be 80 amps.

STARTER SPECIFICATIONS

MOTORCRAFT STARTER SPECIFICATIONS