Disassembly Procedure

TOOLS REQUIRED
^ J8001 Dial Indicator
^ J 26900-13 Magnetic Base
^ J 26900-5 Vernier Caliper
^ J544-01 Tension Scale
^ J 39200 Digital Multimeter




1. Remove the starter motor from the vehicle.
2. Refer to Starting System Description.
3. Remove the nut and the solenoid wire (1) from the solenoid assembly.




4. Remove the two through bolts (1) and separate the field frame (with armature) from the solenoid assembly.




5. Remove the three bolts (1) and the solenoid end cover (2).




6. Inspect the starter solenoid plunger by pressing the plunger in and releasing the plunger. If the plunger does not return to its original position quickly, replace the starter solenoid.
7. Remove the solenoid plunger.




8. Remove the two bolts (2) and separate the drive housing (1) from the solenoid assembly.




9. Inspect the overrunning clutch (1) for wear, damage and other abnormal conditions. Verify that the following conditions exist:
^ The clutch locks when it is turned in the drive direction.
^ The clutch rotates smoothly in the reverse direction. Replace the clutch assembly as necessary.
10. Inspect the overrunning clutch spline teeth (2) for wear and damage. Replace the clutch assembly as necessary.




11. Remove the idler gear (5) from the drive housing.
12. Carefully remove the idler gear roller bearing (1) from the drive housing. The needle bearings may fall out during disassembly.
13. Remove the return spring (3) from the drive housing.
14. Remove the clutch and drive assembly (4) from the drive housing by gently tapping on the pinion end with a rawhide mallet.
15. Inspect the drive housing assembly components for wear, damage or other abnormalities.
16. Replace the components as necessary.
17. Inspect the clutch and drive assembly bearings for wear, damage and smooth operation.
18. Replace the bearings as necessary.




19. Inspect the armature bearings (1) for smooth operation, wear and damage.
20. Replace the bearings as necessary.




21. Remove the steel ball (2) from the clutch and drive assembly.




22. Remove the following components from the field frame:
^ The two screws (3)
^ The end cover (2)
^ The O-ring (discard)




23. Remove the brushes.
24. Hold the spring back with a small screwdriver (2) and remove the brush (4) from the brush holder.
25. Disconnect the four brushes.
26. Remove the brush holder.
27. Remove the armature from the field frame.
28. Inspect the brush springs for corrosion and damage. Replace the components as necessary.
29. Inspect the brush holder and the insulation on the positive plates for wear and damage. Replace the components as necessary.




30. Remove the following from terminal 30 of the solenoid assembly:
30.1. The nut (1)
30.2. The wave washer (2)
30.3. The outside insulator (4)
30.4. The O-ring (5)
30.5. The bolt (11)
30.6. The contact plate (10)
30.7. The inside insulator (8)
30.8. The insulation paper (6)




31. Remove the following from terminal C of the solenoid assembly:
31.1. The nut (9)
31.2. The wave washer (8)
31.3. The outside insulator (7)
31.4. The O-ring (6)
31.5. The bolt (1)
31.6. The contact plate (2)
31.7. The inside insulator (3)