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Repair and Diagnosis: Electrical: Starters: Overhaul: Starter: Reassembly

  1. Reassemble armature washers to the end of armature.
  2. Reassemble armature in field coil housing.
  3. Reassemble rear cover and tighten two brush plate screws to specification. See Figure . See TORQUE SPECIFICATIONS  .
  4. Reassemble drive pinion and stopper on pinion shaft.
  5. Place snap ring on its groove in pinion shaft. See Figure .
  6. Reassemble stopper.
  7. Reassemble lever on drive pinion. See Figure .
  8. If present, reassemble planetary gear set to motor assembly.
  9. Reassemble motor assembly in drive end housing.
  10. Place bolts in rear cover and tighten. See Figure . See TORQUE SPECIFICATIONS  .
  11. Engage plunger in lever. See Figure .
  12. Insert solenoid plunger spring. See Figure .
  13. Reassemble magnetic switch and tighten solenoid screws to specification. See TORQUE SPECIFICATIONS  .
  14. Apply battery power to the "S" terminal and ground starter motor body. Ensure pinion ejects outward and then stops.
  15. Measure clearance (pinion gap) between pinion and stopper.
    CAUTION: Be careful not to let electricity flow continuously for more than 10 seconds.
  16. If pinion gap is not within specified range, adjust it by increasing or decreasing the number of washers used between solenoid and drive housing. The gap will become smaller if the number of washers is increased.
    NOTE: DO NOT use more washers than plates.
  17. Connect field wire to "M" terminal.
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