- Lightly lubricate the
area on the armature shaft that will be under the drive components.
- Install the drive components onto the armature shaft with the
drive away from the armature.
- Install the drive stop collar onto the armature shaft.
- Install the new drive stop retainer ring into the groove on the
shaft.
- Install the thrust collar to the end of the shaft with the small
flange toward the retainer ring.
- Snap the drive stop collar
over the retainer ring using pliers.
- Inspect the bearing in the drive end housing.
| 7.1. | Do not add lubricant. Roller type bearings are permanently lubricated. |
| 7.2. | If the bearing is damaged or dry, replace the bearing using a
small bearing puller. |
| 7.3. | Recess the bearing 1.6 mm (0.06 in) into the housing. |
- Install the shift lever shaft to the thrust collar.
- Install the armature and the drive components into the drive end
housing.
- Install the shift lever shaft in the drive end housing.
- Install the shaft retainer.
- Place the return spring
onto the plunger.
- Press the return spring in order to install the solenoid over
the plunger.
- Align the solenoid with the drive end housing.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the screws.
Tighten
Tighten the screws to 6.5 N·m (60 lb in).
- Replace any damaged brushes.
- Tighten the brushes.
- Clean the brush contact faces in the frame and field with a soft
cloth.
- Install the frame and field components as follows:
| 19.1. | Apply sealer to the solenoid flange where it contacts the frame
and field. |
| 19.2. | Push the brushes into the brush holders and hold. |
| 19.3. | Install the frame and the field components over the armature. |
| 19.4. | Align the frame and field components to the drive end housing. |
| 19.5. | Release the brushes onto the commutator. |
| 19.6. | Inspect that all four brushes move freely in the holders. |
| 19.7. | Inspect that the brushes are in contact with the commutator. |
- Install the brake washer onto the armature shaft.
Important: Do not lubricate the bearing. Roller type bearings are permanently lubricated.
- Inspect the bearing in the commutator end frame.
- Replace the bearing if it is damaged or dry using a small bearing
puller.
Tighten
Recess the bearing 2 mm (0.08 in) into the housing.
- Install the commutator end frame onto the armature shaft.
- Align the commutator end frame and the frame with field.
- Install the identification tag onto one through bolt.
- Install the starter motor through bolts.
If the through bolts have different heads, install as noted during disassembly.
Tighten
Tighten the bolts to 8.5 N·m (75 lb in).
- Inspect the drive pinion clearance.
- Install the solenoid terminal field lead.
Tighten
Tighten the field lead screw to 8.5 N·m (75 lb in).
- Install the starter motor. Refer to
Starter Motor Replacement
.
