Overhaul
Starter Overhaul
Disassembly/Reassembly
Brush Holder Removal
1. Remove the starter.
2. Disconnect the wire from the M terminal, and remove the end cover.
3. Place a 29.4 mm (1.16 in.) outside diameter plastic pipe on the armature
4. Move the brush holder (A) up to the pipe (B) while holding the pipe so the brushes do not pop out from the holder.
Armature Inspection and Test
5. Disassemble the starter as shown at the beginning of this procedure.
6. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
7. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).
8. Check the commutator diameter. If the diameter is bellow the service limit, replace the armature.
Commutator Diameter
Standard (New): 29.3 - 29.5 mm (1.154 - 1.161 in.)
Service Limit: 28.8 mm (1.134 in.)
9. Measure the commutator (A) runout.
- If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
- If the commutator runout is not within the service limit, replace the armature.
Commutator Runout
Standard (New): 0.05 mm (0.002 in.) max.
Service Limit: 0.1 mm (0.004 in.)
10. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth
Standard (New): 0.40 - 0.60 mm (0.016 - 0.024 in.)
Service Limit: 0.20 mm (0.008 in.)
11. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
12. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attached to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
13. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.
Starter Brush Inspection
14. Measure the brush length (A). If it is shorter than the service limit, replace the brush holder assembly.
Brush Length
Standard (New): 7.7 - 8.0 mm (0.30 - 0.31 in.)
Service Limit: 0.9 mm (0.04 in.)
Starter Brush Holder Test
15. Check that there is no continuity between the (+) brush (A) and (-) brush (B). If there is continuity, replace the brush holder assembly.
Planetary Gear Inspection
16. Check the planetary gears (A) and ring gear (B). Replace the them if they are worn or damaged.
Overrunning Clutch Inspection
17. Slide the overrunning clutch along the shaft. Replace it, if it does not slide smoothly.
18. Rotate the overrunning clutch (A) both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.
19. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the flywheel ring gear to see, if the starter drive gear teeth are damaged.
Starter Reassembly
20. Install the armature into the housing.
21. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.
22. Install the end cover to retain the brush holder.
MITSUBA (A/T)
Disassembly/Reassembly
Armature Inspection and Test
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.
Commutator Diameter
Standard (New): 28.0 - 28.1 mm (1.102 - 1.106 in.)
Service Limit: 27.5 mm (1.083 in.)
6. Measure the commutator (A) runout.
- If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
- If the commutator runout is not within the service limit, replace the armature.
Commutator Runout
Standard (New): 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).
Commutator Mica Depth
Standard (New): 0.40 - 0.50 mm (0.016 - 0.020 in.)
Service Limit: 0.15 mm (0.006 in.)
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.
Starter/Brush Inspection
11. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.
Brush Length
Standard (New): 11.1 - 11.5 mm (0.44 - 0.45 in.)
Service Limit: 4.3 mm (0.17 in.)
Starter Brush Holder Test
12. Check that there is no continuity between the (+) brush (A) and (-) brush (B). If there is continuity, replace the brush holder assembly.
Planetary Gear Inspection
13. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged.
Overrunning Clutch Inspection
14. While holding the drive gear (A), turn the gear shaft (B) clockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover assembly.
15. While holding the drive gear, turn the gear shaft counterclockwise. The gear shaft should rotate freely. If the gear shaft does not rotate smoothly, replace the gear cover assembly.
16. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.
Check the condition of the torque converter ring gear to see if the starter drive gear teeth are damaged.
Starter Reassembly
17. Install the brush into the brush holder, and set the armature (A) in the brush holder (B).
NOTE: To seat the new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
18. While squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (D, E and F).
19. Install the armature and brush holder assembly into the housing.
NOTE: Make sure the armature stays in the holder.