Pinion Gap Adjustment Test
- Disconnect field lead from terminal "M" of solenoid to prevent starter from operating. See Fig 1 . Connect jumper wire from 12-volt battery positive terminal to terminal "S" of solenoid.
- Connect another jumper wire from negative battery terminal to terminal "M" of solenoid. Solenoid should energize when battery is connected, extending out drive pinion. With drive pinion extended, measure pinion gap between drive pinion and collar. Gap should be 0.02-0.08" (0.5-2.0 mm).NOTE: DO NOT engage solenoid for longer than 10 seconds. If test must be repeated, wait at least 3 minutes between tests to allow solenoid to cool.
- Add or subtract shims between solenoid and end housing to achieve proper pinion depth gap. Install field lead to terminal "M" of solenoid. Install nut and tighten to 71-106 INCH lbs. (8-12 N.m).