Starter - Gear Reduction: Other Mazda 626 GD

INHIBITOR SWITCH (A/T)

RX7 (Without Theft Deterrent Control)

1) Switch harness connector is located near starter. Ensure transmission gear selector is in Park position and ignition switch is in START position. Using test light, backprobe Black/Yellow wire terminal at inhibitor switch harness connector.

2) If test light does not illuminate, check fuse No. 8 of fuse block and/or repair open in Black/Yellow wiring circuit between inhibitor switch and fuse block fuse No. 8. At fuse No. 8 Black/Yellow wire color changes to Black/Red to continue wiring circuit to ignition switch.

3) If test light does illuminate, backprobe Black/Red wire terminal at inhibitor switch harness connector. If test light does not illuminate now, adjust or replace switch.

Except RX7 (Without Theft Deterrent Control)

1) Switch is located on transmission manual shift shaft. Disconnect starter solenoid wire at "S" terminal. Ensure transmission gear selector is in Park position and ignition switch is in START position. Using test light, backprobe Black/Yellow wire (Green wire on MPV) terminal at inhibitor switch harness connector.

2) If test light does not illuminate, repair open in Black/Yellow wiring (Green wiring on MPV) circuit between ignition switch and inhibitor switch harness connector. If test light does illuminate, backprobe Black/Red wire terminal at inhibitor switch harness connector. If test light does not illuminate now, adjust or replace switch.

STARTER CUT RELAY

Models With Theft Deterrent Control

See appropriate chassis wiring diagram in WIRING DIAGRAMS.

STARTER INTERLOCK SWITCH (CLUTCH START SWITCH)

Switch is mounted on bracket near top front of clutch pedal. Disconnect switch harness connector. Using ohmmeter, ensure continuity exists between switch connector terminals when clutch pedal is depressed. If continuity does not exist, adjust or replace switch.

SOLENOID TESTS

Note. Solenoid tests must be performed with starter assembled and field wire from starter disconnected at solenoid terminal "M".

Solenoid

1. Disconnect all wires to solenoid. Using ohmmeter, ensure continuity between "S" and "M" terminals, and between "S" terminal and solenoid body. see scheme 1 If continuity does not exist between these terminals, solenoid must be replaced.
2. Ensure continuity does not exist between "M" and "B" terminals. If continuity exists between these terminals, solenoid is shorted and must be replaced.

Scheme 3

1. Ensure field wire is disconnected from solenoid "M" terminal. Connect positive battery lead to "S" terminal and negative battery lead to starter case. Starter pinion drive gear will extend outward and stop.
2. Quickly measure pinion gap clearance between end of pinion drive and circlip retainer. (Scheme 3) DO NOT operate starter solenoid for more than 10 seconds. Pinion gap clearance should be.02-.08" (0.5-2.0 mm).
3. If pinion gap clearance is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing. (Scheme 3)

BRUSH TESTS

1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, brush holder assembly is shorted and must be replaced.
2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If less than specification, replace brushes. Use brush spring scale to check spring tension. Spring tension is measured at point where spring separates from brush. Tension should be greater than 1.5 lbs. (0.7 kg). Tension specification for a new spring is 4.0-5.3 lbs. (1.8-2.4 kg). Brushes must move freely in holders.

BRUSH LENGTH SPECIFICATIONS

OVERRUNNING CLUTCH PINION DRIVE

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 clean overrunning clutch with solvent, as it is packed with grease and sealed by manufacturer.

MPV 4WD

1. Disconnect negative battery cable. Remove alternator and power steering (P/S) belts. Remove P/S pulley. Remove alternator harness connector and battery cable. Remove alternator. Remove 2 engine undercovers. DO NOT disconnect P/S pump hoses, but remove P/S pump from brackets to enable removal of A/T oil cooler line brackets behind pump. Remove front driveshaft.
2. Remove wiring harness bracket bolts, heat shield and A/T oil cooler line bracket bolt from rear of engine, near starter. Disconnect starter wires. Remove fuel and brake line cover on frame rail. Remove starter. Remove lower starter mounting bolt last. To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS table at end of this article.

Except MPV 4WD

1. Disconnect negative battery cable. Raise vehicle on hoist. Remove undercover. Disconnect wiring from starter. Remove differential lock assembly on 4WD models. On MX-6, Protege (A/T), and 626 models, remove support brace from under intake manifold. Remove starter mounting bolts. Remove lowest mounting bolt last. Remove starter from under side of vehicle.
2. To install starter, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS table at end of this article.

Coaxial Planetary Gear Type

1. Remove solenoid housing, plunger and spring from starter. (Scheme 5) Remove rear cover. Mark components for reassembly reference. Remove brush plate. Remove armature. Ensure thrust ball located inside gear shaft or on end of armature DOES NOT get misplaced.
2. Remove planetary gears from gear shaft. Remove front drive housing and yoke lever. Use arbor press to remove circlip, stopper and drive pinion from gear shaft. (Scheme 4) Remove overrunning clutch, thrust shim and internal gear plate from gear shaft.
3. To assemble, reverse disassembly procedures. Lubricate following components during reassembly: armature shaft gear teeth, internal and planetary gears, solenoid plunger, yoke lever and armature thrust ball, and bushings.
4. Assemble internal gear plate, thrust shim and overrunning clutch on the gear shaft. Use arbor press and overrunning clutch to install stopper and circlip on armature shaft. (Scheme 4) Ensure brush plate, rear cover and internal gear plate are aligned when installing through bolts.

Scheme 4

Offset Gear Type

1. Remove through bolts and rear cover. (Scheme 6) Remove brush plate, armature and field coil housing. Remove solenoid and shims from front housing. Remove center support plate and yoke lever from front housing.
2. Remove pinion drive circlip cover and retainer circlip. Remove pinion drive/reduction gear assembly. To assemble, reverse removal procedures. Lubricate all bushing and thrust surfaces.

Scheme 5

Scheme 6