Disassembly and Assembly

DISASSEMBLY







1. Disconnect the M-terminal wire from the M-terminal.







2. Remove the starter solenoid screws.







3. Remove the starter solenoid from the drive end housing.







4. Remove the thru bolts.







5. Separate the starter field coil from the drive end housing.
6. Remove the armature thrust ball from the starter motor armature.







7. Remove the drive end yoke gasket from the drive end housing.







8. Remove the three planet gears from the output shaft.







9. Remove the drive lever disc stop.







10. Remove the drive lever disc.







11. Remove the output shaft and drive lever and pin from the drive end housing.







12. Use a 14 mm socket to drive the stop ring retainer off the starter drive stop ring.
13. Pry the starter drive stop ring off of the output shaft.
14. Remove the stop ring retainer.







15. Remove the starter drive from the output shaft.







16. Remove the stationary gear from the output shaft.
17. Remove the brush end plate and bushing screws.







18. Remove the brush end plate and bushing from the starter field coil.







19. Remove the brush set from the starter motor armature.







20. Remove the starter motor armature from the starter field coil.

ASSEMBLY

1. Install the starter motor armature in the starter field coil.
2. Install the brush set on the starter motor armature.
3. Install the brush end plate and bushing on the brush set. Tighten the brush end plate and bushing screws to 3-4 N.m (27-35 lb-in).
4. Install the stationary gear on the output shaft.
5. Install the starter drive on the output shaft.
6. Install the stop ring retainer.
7. Install the starter drive stop ring.







8. Use Bearing Pulling Attachment D84L-1122-A or equivalent to press the stop ring retainer over the starter drive stop ring.
9. Install the output shaft and drive lever and pin in the drive end housing.

NOTE: Apply grease to the drive lever and pin and body prior to installation.

10. Install the drive lever disc.
11. Insert the drive lever disc stop.
12. Install the three planet gears.
13. Install the drive end yoke gasket in the drive end housing.
14. Install the armature thrust ball on the starter motor armature.

NOTE: Use a dab of grease on the end of the starter motor armature to retain the armature thrust ball when installing the starter field coil on the drive end housing.

15. Install the starter field coil on the drive end housing.
16. Install the thru bolts. Tighten the thru bolts to 4-7 N.m (36-61 lb-in).
17. Install the starter solenoid on the drive end housing. Tighten the starter solenoid screws to 4-7 N.m (36-61 lb-in).
18. Install the M-terminal wire on the starter solenoid. Tighten the M-terminal nut to 8-12 N.m (71-106 lb-in).