Starter Overhaul SD Series

1. Remove the starter motor.

Refer to Starter Motor Replacement in Engine Electrical.

2. Remove the solenoid terminal field lead screw.
3. Remove the following components from the starter motor:

3.1.	The through bolts

3.2.	The identification tag

3.3.	The commutator end frame

Note the location of the through bolt heads relative to the field lead for assembly.

4. Remove the brake washer from the armature shaft.
5. Remove the frame with field from the armature.
6. Tilt the armature in order to disengage the drive collar from the shift lever.
7. Remove the armature with the drive from the drive end frame.



8. Disassemble the starter solenoid.
9. Remove the shift lever shaft retaining ring from the drive end housing.
10. Remove the shift lever shaft.

If the shaft is staked into place, perform the following:

10.1.

Use a drill in order to remove the stake.

10.2.

Remove the drive shaft.

10.3.

Discard the shaft and the retainer.

11. Remove the plunger with the return spring from the drive end housing.



12. Remove the thrust collar from the armature shaft.
13. Remove the drive stop collar from the retainer ring.

The collar will remain on the shaft next to the drive pinion.

14. Bend the retainer ring enough to avoid scratching the armature shaft and remove the ring from the groove in the armature shaft.
15. Discard the ring.
16. Remove the drive stop collar from the shaft.
17. Remove the drive from the shaft.

1. Lightly lubricate the area on the armature shaft that will be under the drive components.
2. Install the drive components onto the armature shaft with the drive away from the armature.
3. Install the drive stop collar onto the armature shaft.
4. Install the new drive stop retainer ring into the groove on the shaft.
5. Install the thrust collar to the end of the shaft with the small flange toward the retainer ring.



6. Snap the drive stop collar over the retainer ring using pliers.
7. 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.

8. Install the shift lever shaft to the thrust collar.
9. Install the armature and the drive components into the drive end housing.
10. Install the shift lever shaft in the drive end housing.
11. Install the shaft retainer.



12. Place the return spring onto the plunger.
13. Press the return spring in order to install the solenoid over the plunger.
14. Align the solenoid with the drive end housing.
15. Install the screws.

Tighten
Tighten the screws to 6.5 N·m (60 lb in).

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.

16. Replace any damaged brushes.
17. Tighten the brushes.
18. Clean the brush contact faces in the frame and field with a soft cloth.
19. 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.

20. Install the brake washer onto the armature shaft.
21. Inspect the bearing in the commutator end frame.

•	Do not lubricate the bearing. Roller type bearings are permanently lubricated.

•	Replace the bearing if it is damaged or dry using a small bearing puller.

•	Recess the bearing 2 mm (0.08 in) into the housing.

22. Install the commutator end frame onto the armature shaft.
23. Align the commutator end frame and the frame with field.
24. Install the identification tag onto one through bolt.
25. 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).

26. Inspect the drive pinion clearance.

Refer to Starter Pinion Clearance Check in Engine Electrical.

27. Install the solenoid terminal field lead.

Tighten
Tighten the field lead screw to 8.5 N·m (75 lb in).




28. Install the starter motor.

Refer to Starter Motor Replacement in Engine Electrical.