5-06
Starting System
5-06
7.
Install a new stop-ring retainer. Partially fill the drive end
housing bearing bore with grease (approximately 1/4 full).
Position the starter drive plunger lever return spring and
drive end housing to the starter frame, and then tighten the
through bolts to specifications 55-75 inch pounds).
8. Position the starter drive plunger lever cover and the brush
cover band, with its gasket, on the starter. Tighten the brush
cover band retaining screw.
BRUSH REPLACEMENT
Replace the starter brushes when they are worn to inch.
Always install a complete set of new brushes.
1. Loosen and remove the brush cover band, gasket, and
starter drive plunger lever cover. Remove the brushes from
their holders.
2. Remove the two through bolts from the starter frame.
3. Remove the drive end housing, and the plunger lever return
spring.
4. Remove the starter drive plunger lever pivot pin and lever,
and remove the armature.
FIG 12 Coil Assembly
5. Remove the brush end plate.
9.
Position the starter brush end plate to the frame with the end
6. Remove the ground brush retaining screws from the frame
plate boss in the frame slot.
and remove the brushes.
10. Apply a thin coating of Lubriplate 777 on the armature shaft
7. Cut the insulated brush leads from the field coils, as close to
splines. Install the starter motor drive gear assembly to the
the field connection point as possible.
armature shaft and install a new retaining stop ring. Install a
8. Clean and inspect the starter motor.
new stop retainer.
9. Replace the brush end plate if the insulator between the field
11. Position the fiber thrust washer on the commutator end of
brush holder and the end plate is cracked or broken.
the armature shaft and position the armature in the starter
10. Position the new insulated field brushes lead on the field coil
frame.
connection. Position and crimp the clip provided with the
12. Partially fill the drive end housing bearing bore with grease
brushes to hold the brush lead to the connection. Solder the
(approximately 1/4 full). Position the starter drive gear
lead. clip, and connection together, using rosin core
plunger lever to the frame and starter drive assembly, and
solder(Figure 12). Use a 300-watt iron II. Install the ground
install the pivot pin.
brush leads to the frame with the retaining screws.
13. Position the starter drive plunger lever return spring and the drive
12. Clean the commutator with 00 or 000 sandpaper.
end housing to the frame and install and tighten the through bolts to
13. the brush end plate to the starter frame, with the end plate
specification (55-75 inch pounds). Do not pinch the brush leads
boss in the frame slot.
between the brush plate and the frame. Be sure that the stop ring
13. Position the brush end plate to the starter frame. with the
retainer is seated properly in the drive housing.
end plate boss in the frame slot.
14. Install the brushes in the brush holders. Be sure to center
14. Install the armature in the starter frame.
the brush springs on the brushes.
15. Install the starter drive gear plunger lever to the frame and
15. Position the drive gear plunger lever cover on the starter and
starter drive assembly, and install the pivot pin.
install the brush cover band with a gasket. Tighten the band
16. Partially fill the drive end housing bearing bore with grease
retaining screw.
(approximately 1/4 full). Position the return spring on the
16. Check the starter no-load current draw.
plunger lever, and the drive end housing to the starter frame.
Starter Drive Replacement
Install the through bolts and tighten to specified torque (55-
1. Loosen and remove the brush cover band and the starter
75 inch pounds). Be sure that the stop ring retainer is seated
drive plunger lever cover (Figure 8).
properly in the drive end housing.
2. Loosen the through bolts enough to allow removal of the
17. Install the commutator brushes in the brush holders. Center
drive end housing and the starter drive plunger lever return
the brush springs on the brushes.
spring.
18. Position the plunger lever cover and the brush cover band,
3. Remove the pivot pin retaining the starter drive plunger lever
with its gasket on the starter. Tighten the band retaining
and remove the lever.
screw.
4. Remove the drive gear stop ring retainer and stop ring from
19. Connect the starter to a battery to check its operation.
the end of the armature shaft and remove the drive gear
ARMATURE REPLACEMENT
assembly.
1. Loosen the brush cover band retaining screw and remove
5. Apply a thin coating of Lubriplate 777 on the armature shaft
the brush cover band, gasket, and the starter drive plunger
splines. Install the drive gear assembly on the armature
lever cover. Remove the brushes from their holders.
shaft and install a new stop ring.
2. Remove the through bolts, the drive end housing, and the
6. Position the starter gear plunger lever on the starter frame
drive plunger lever return spring.
and install the pivot pin. Be sure that the plunger lever
properly engages the starter drive assembly.
