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Pinion Gap Adjustment

NOTE: Reduction gear drive starter pinion gap is adjustable. Direct drive starter pinion gap is not adjustable.
  1. Disconnect field coil wire from terminal "M" at starter solenoid. See Figure and Figure . Connect a remote starter switch between positive battery terminal and terminal "S" of solenoid. Connect a jumper wire from negative battery terminal to terminal "M" of starter solenoid.
  2. Turn remote starter switch on for no longer than 10 seconds. Pinion will move out when solenoid is energized. Using feeler gauge, measure clearance between pinion and stopper. See Fig 1 .
  3. Clearance should be .020-.079" (0.5-2.0 mm). Add or remove gaskets between solenoid and front housing to adjust clearance. See Figure .
Fig 1: Measuring Pinion Gap
G91G00017Courtesy of CHRYSLER CORP.
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