Starter Solenoid Replacement 3100 Engine L82

1. Remove the starter motor from the engine. Refer to Starter Motor Replacement .
2. Remove nuts from the solenoid to frame and field.
3. Remove the screws from solenoid retaining clamp.
4. Remove the heat shield if used.
5. Pull the solenoid straight out. Solenoid to frame opening has a plug rather than sealant.

Notice: Use only 10477431 grease to lubricate solenoid core. This grease is specially formulated to aid plunger movement and dampen vibration of the plunger as the engine runs. Other greases may eventually degrade and prevent proper plunger movement, causing starter failure.

1. Lubricate the solenoid core.

•	Apply one complete packet of 10477341 grease evenly around the inside edge of the solenoid core.

•	Apply grease thickly to the first 13 mm (0.5 in) inside the edge of the core. Plunger movement will distribute grease properly.

•	Avoid getting dirt or other contamination in grease before installing solenoid to starter.

2. Install the solenoid over the plunger by compressing the spring.
3. Align the solenoid motor field terminal M with the field lead on the starter motor.
4. Place the clamp over the solenoid.
5. Align the clamp to the drive end housing.
6. Install solenoid clamp attachment screws.

Tighten
Tighten the attachment screws to 11 N·m (95 lb in).

7. Install the heat shield (if used) to the extended ends of the solenoid clamp attachment screws.

Tighten
Tighten the attachment screws to 8.5 N·m (75 lb in).

8. Install the nut to solenoid terminal to field connector.

Tighten
Tighten the nut to 9.5 N·m (84 lb in).

9. Install the starter motor to the engine. Refer to Starter Motor Replacement .

Starter Solenoid Replacement 3800 Engine L36

1. Remove the starter motor from the engine. Refer to Starter Motor Replacement .
2. Remove the screw at the field connector.
3. Remove two screws at the field connector.
4. Remove the solenoid by rotating 90 degrees.

Notice: Use only 10477431 grease to lubricate solenoid core. This grease is specially formulated to aid plunger movement and dampen vibration of the plunger as the engine runs. Other greases may eventually degrade and prevent proper plunger movement, causing starter failure.

1. Lubricate the solenoid core.

•	Apply one complete packet of 10477341 grease evenly around the inside edge of the solenoid core.

•	Apply grease thickly to the first 13 mm (0.5 in) inside the edge of the core. Plunger movement will distribute grease properly.

•	Avoid getting dirt or other contamination in grease before installing solenoid to starter.

2. Install the solenoid over the plunger by compressing the spring.
3. Rotate the solenoid 90 degrees in order to install the housing.
4. Install solenoid attachment screws.

Tighten
Tighten the attachment screws to 65 N·m (60 lb in).

5. Install the screw to solenoid terminal with field connector.

Tighten
Tighten the nut to 85 N·m (75 lb in).

6. Install the starter motor to the engine. Refer to Starter Motor Replacement .