Starter 3.0L: Starter: Disassembly

Loosen nut which holds terminal M of switch assembly, and disconnect connector.

Fig 1: Loosening Terminal "M" Nut & Disconnecting Connector
Remove bolts which hold switch assembly, and remove switch assembly, plunger and plunger spring from starter as a unit.
CAUTION: Be careful because pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.

Fig 2: Removing Bolts Holding Switch Assembly
Remove both through-bolts and brush holder screws, and detach rear bracket and brush holder.

Fig 3: Removing Through-Bolts & Brush Holder
Remove armature and yoke. Ball used as a bearing will then be removed from the end of armature.
CAUTION: Be sure to mark an alignment mark on yoke and front bracket before removing yoke.

Fig 4: Removing Armature & Yoke
Remove packing A, three planetary gears, packing B and plate.

Fig 5: Exploded View Of Planetary Gears & Components
Remove shaft assembly and overrunning clutch as a unit.
CAUTION: Record the direction of lever before removing.

Fig 6: Removing Shaft Assembly & Overrunning Clutch
Remove overrunning clutch from shaft assembly as follows:
1. Remove stopper from ring by lightly tapping a fit tool placed on stopper.
2. Remove ring stopper and clutch from shaft.
  
  Fig 7: Removing Ring Stopper & Clutch From Shaft