Starter Assembly (SD-255)

SD-255 Brush Holder:

Commutator End Bearing Installation:

Testing Field For Ground:

ASSEMBLE
1. Drive assembly to armature shaft as follows:
1. Lightly lubricate area on armature shaft that will be under drive assembly with GM lubricant.
2. Drive assembly onto armature shaft with pinion away from armature.
3. Pinion stop collar onto armature shaft.
4. New pinion stop retainer ring into groove on shaft. Do not reuse old ring.
5. Thrust collar to end of shaft with small flange toward retainer ring. Use pliers as to snap pinion stop collar over retainer ring.
Inspect

Checking Pinion Clearance:

1. Bearing in drive end housing. Roller type bearing is permanently lubricated. Do not add lubricant. If damaged or dry, replace bearing using a small bearing puller (Snap-One tool CG40CB or equivalent). Recess hearing 1.6 mm (0.06 in.) into housing, refer to Figure above.
2. Shift lever yoke to drive collar, then armature/drive/lever assembly into drive end housing.
3. Shift lever shaft through holes in drive end housing and shift lever, then secure with retainer. Place return spring onto plunger.
4. Solenoid over plunger by depressing spring, aligning to drive end housing. Install attaching screws.
Tighten
^ Attaching screws to 6.5 N.m (60 lb. in.).

Armature Shaft And Drive Assembly:

^ Brushes. When damaged or excessively worn replace brushes.
^ Use soft cloth to clean brush contact faces in frame and field assembly.
5. Frame and field assembly as follows:
1. Apply sealer to solenoid flange where frame and field will contact.
2. Push brushes into brush holders and hold.
3. Install frame and field assembly over armature, aligning properly to drive end housing.
4. Release brushes onto commutator. Be sure all four brushes move freely in holders and are in contact with commutator.
5. Brake washer onto armature shaft.
Inspect

Drive End Housing Bearing:

^ Bearing in commutator end frame. Roller type bearing is permanently lubricated. Do not add lubricant. If damaged or dry, replace bearing using a small hearing puller (Snap-On tool A78 or equivalent). Recess bearing 2 mm (0.08 in.) into housing.
6. Commutator end frame onto armature shaft, aligning with frame and field assembly.
7. Identification tag onto one through bolt, then both through bolts to motor. When through bolts have different heads, place as noted during disassembly.
Tighten
^ Through bolts to 8.5 N.m (75 lb. in.).
Measure
^ Pinion clearance, refer to "Checking Pinion Clearance".
8. Field lead to solenoid terminal. Checking Pinion Clearance
Tighten
^ Attaching screw to 8.5 N.m (75 lb. in.).