Starter Motor Replacement
Starter Motor Replacement: Removal Procedure:
REMOVAL PROCEDURE
NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor
1. Disconnect the negative battery cable.
2. Remove the front exhaust pipe.
3. Remove the wires from the starter solenoid.
Starter Motor Replacement: Removal Procedure:
4. Remove the starter motor mounting bolts.
Starter Motor Replacement: Removal Procedure:
5. Remove the starter from the vehicle.
6. Remove the starter shims, if equipped.
INSTALLATION PROCEDURE
Starter Motor Replacement: Removal Procedure:
1. Install the starter to the vehicle.
Starter Motor Replacement: Removal Procedure:
2. Install the inboard starter mounting bolt. Do not tighten.
3. Install the starter shims to the vehicle, if equipped.
4. Install the outboard starter mounting bolt.
Tighten
Tighten the starter mounting bolts to 43 N.m (32 lb ft).
Starter Motor Replacement: Removal Procedure:
5. Connect the wires to the solenoid.
6. Install the flywheel cover.
7. Connect the negative battery cable.
STARTER MOTOR REPLACEMENT (4.3L 4WD)
REMOVAL PROCEDURE
Starter Motor Replacement: Removal Procedure:
1. Disconnect the negative battery cable.
2. Disconnect the engine mounts.
3. Raise the engine.
4. Support the engine.
5. Remove the transmission mount.
6. Support the transmission assembly.
7. Remove the starter mounting bolts. Rotate the starter for access.
Starter Motor Replacement: Removal Procedure:
8. Remove the wires from the solenoid.
Starter Motor Replacement: Removal Procedure:
9. Remove the starter from the vehicle. Note the location of the shims, if equipped.
INSTALLATION PROCEDURE
Starter Motor Replacement: Removal Procedure:
1. Install the starter to the vehicle.
Starter Motor Replacement: Removal Procedure:
2. Connect the wires to the solenoid.
Starter Motor Replacement: Removal Procedure:
3. Install the inboard starter mounting bolt. Do not tighten.
4. Install the starter shims and the outboard starter mounting bolt.
Tighten
Tighten the starter mounting bolts to 43 N.m (32 lb ft).
5. Lower the engine assembly onto the mounts.
- Connect the transmission mount.
- Connect the engine mounts.
6. Connect the negative battery cable.
STARTER MOTOR REPLACEMENT (4WD Utility)
REMOVAL PROCEDURE
Starter Motor Replacement: Removal Procedure:
1. Place the vehicle on a hoist.
2. Disconnect the negative battery cable.
3. Disconnect the starter solenoid wiring.
4. Raise the vehicle on the hoist.
5. Remove the transfer case shield.
6. Remove the bolts and the two brackets holding the brake pipe to the transmission crossmember.
7. Remove the transmission crossmember attaching bolts, three bolts per side.
8. Remove the transmission mount bolts.
9. Support the transmission assembly.
10. Slide the transmission crossmember out of the way.
11. Remove the bracket that holds the transmission fluid cooler lines to the flywheel housing.
12. Remove the brace rod to the flywheel housing.
13. Remove the lower flywheel housing.
Starter Motor Replacement: Removal Procedure:
14. Remove the two bolts that hold the starter motor to the engine.
Starter Motor Replacement: Removal Procedure:
15. Remove the starter from the vehicle.
16. Remove the shims, if equipped.
INSTALLATION PROCEDURE
Starter Motor Replacement: Removal Procedure:
1. Install the starter motor to the engine.
Starter Motor Replacement: Removal Procedure:
2. Install the inboard starter mounting bolt. Do not tighten the bolt.
3. Install the starter shims and the outboard starter mounting bolt.
Tighten
Tighten the starter mounting bolts to 43 N.m (32 lb ft).
4. Install the lower flywheel cover.
5. Connect the transmission line bracket to the flywheel housing.
6. Connect the brace rod to the flywheel housing.
7. Slide the transmission crossmember back into place.
8. Attach the transmission mount to the transmission.
9. Connect the transmission crossmember to the frame with the six bolts.
10. Connect the two brake line brackets to the transmission crossmember.
11. Install the transfer case shield, if equipped.
Starter Motor Replacement: Removal Procedure:
12. Connect the starter solenoid wiring.
13. Lower the vehicle.
14. Connect the negative battery cable.