DESCRIPTION
The direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. It is manufactured by Nippondenso. The integral solenoid is attached to the drive housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch pinion drive is mounted directly on the drive end of armature shaft.
Note. B2200 models equipped with automatic transmissions use a gear reduction type starter. See STARTERS - GEAR REDUCTION article in this section.
Voltage Supply Test
Ensure battery is fully charged. Turn ignition switch to "start" position and ensure starter operates. If starter does not operate, use a voltmeter to check the voltage between "S" terminal and ground. If voltage is less than 8 volts, wiring harness is faulty. If voltage is greater than 8 volts and starter is inoperative, there is an internal starter fault.
No-Load Test
With starter on bench, connect a fully-charged 12-volt battery to starter. Connect a voltmeter and ammeter to starter circuit. (Scheme 1) Check no load specification. See NO LOAD TEST SPECIFICATIONS table. If not within specifications, disassemble and inspect starter components.
| Application | Specification |
|---|---|
| Voltage | 11.5 Volts |
| Current | 60 Amps (Maximum) |
| Shaft Speed | 6500 RPM |
NO-LOAD TEST SPECIFICATIONS
Scheme 1
| CAUTION | Do not engage starter solenoid for more than 10 seconds during testing or damage to coil winding may result. |
Note. Tests must be performed with starter assembled and field lead ("M") from starter disconnected at the solenoid.
Solenoid Pull-In & Holding Test
Disconnect "M" wire between solenoid and armature. Connect battery negative to solenoid case and to terminal "M". Connect contact "S" to battery positive. Starter pinion gear should move outward and maintain this position. If starter pinion gear does not move out, replace solenoid. During test, disconnect the battery negative at terminal "M". Starter pinion gear should stay out. If not, replace solenoid. (Scheme 1)
Pinion Gear Return Test
Connect battery to terminal "M" and ground solenoid case. Use a screw driver to pull pinion out manually. When released, pinion should immediately return to its original position.
Pinion Gap Adjustment
Disconnect solenoid-to-starter connection (terminal "M"). When battery is connected between terminal "S" and starter case, pinion will move outward and stop. Measure clearance (pinion gap) between pinion teeth and circlip retainer. DO NOT operate starter for more than 20 seconds. Pinion gap should be.020-.079" (0.5-2.0 mm). If pinion gap is not within specifications, adjust by increasing or decreasing the thickness of the shims located between the solenoid and drive housing. (Scheme 3)
Armature
- Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
- Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, the armature is shorted and must be replaced. Check continuity between commutator and shaft. If continuity exists, replace armature.
- Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.
Commutator
- Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.
- Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. COMMUTATOR SPECIFICATIONS Application Maximum Runout Minimum Diameter 323 .004" (.10 mm) 1.22" (31 mm)
- Commutator mica undercut depth should be .02-.03" (.5-.8 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.
Brushes & Springs
- Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If test needle moves, brush holder assembly is shorted and must be replaced.
- Check brush length. Brush should not be worn beyond limit line. If less than specification, replace brushes. Use a brush spring scale to check spring tension. Spring tension is measured at point where spring separates from brush. Tension should be greater than 2 lbs. (0.9 kg.). Tension specification for a new spring is 3.1-5.7 lbs. (1.4-2.6 kg.). Brushes must move freely in holders. (Scheme 3)
Field Coils
- Connect one ohmmeter lead to field coil lead from starter solenoid. Connect other lead to soldered portion of brush lead. If there is no continuity, repair or replace field coil.
- Check field coil for shorts to ground by connecting a test lead to field coil lead. Connect other lead to starter housing. If continuity exists, repair or replace field coil.
Overrunning Clutch
Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions, clutch is faulty and must be replaced. DO NOT wash overrunning clutch with solvent, it is packed with grease and sealed by manufacturer.
Solenoid
Check continuity between terminals "S" and "M". Check continuity between terminal "S" and solenoid body. There must be continuity between these terminals or solenoid must be replaced. Check continuity between terminals "M" and "B". If continuity exists between these terminals, solenoid is shorted and solenoid must be replaced.
REMOVAL & INSTALLATION
Disconnect negative battery terminal. Disconnect wiring from starter. Remove differential lock assembly (4WD models). Remove 2 mounting bolts and remove starter from lower side of vehicle. To install starter, reverse removal procedure. Tighten mounting bolts to 23-24 ft. lbs. (31-46 N.m). Tighten "B" battery terminal to 87-104 INCH lbs. (9.8-12 N.m).
DISASSEMBLY & ASSEMBLY
Mark yoke, rear cover and front cover for reassembly reference. Remove solenoid, rear cover and brush holder. Remove field housing and pull amature and yoke from drive housing. Use a piece of pipe or tubing to remove overrunning clutch circlip retainer. Reverse removal procedure to assemble.
