Starter Overhaul

Fig 1: Exploded View Of Starter Disassembly/Reassembly - M/T

Fig 2: Exploded View Of Starter Disassembly/Reassembly - A/T

Armature Inspection and Test 

1. Remove the starter (see Starter Replacement  ).
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 3: Inspecting Armature

   
4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with 500 or 600 sandpaper (B).
   Fig 4: Checking Commutator Surface

   
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

   Commutator Diameter 

   Standard (New): 

   • M/T:  27.9-28.0 mm (1.098-1.102 in.)
   • A/T:  28.0 mm-28.1 mm (1.102-1.106 in.)

   Service Limit: 

   • M/T:  27.0 mm (1.063 in.)
   • A/T:  27.5 mm (1.083 in.)
   Fig 5: Checking Commutator Diameter

   
6. Measure the commutator (A) runout.
   • If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
   • If the commutator runout is not within the service limit, replace the armature.

   Commutator Runout 

   • Standard (New):  0.02 mm (0.001 in.) max.
   • Service Limit:  0.05 mm (0.002 in.)
   Fig 6: Measuring Commutator Runout

   
7. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).

   Commutator Mica Depth 

   Standard (New): 

   • M/T:  0.45-0.75 mm (0.018-0.030 in.)
   • A/T:  0.4-0.5 mm (0.016-0.020 in.)

   Service Limit: 

   • M/T:  0.2 mm (0.008 in.)
   • A/T:  0.15 mm (0.006 in.)
   Fig 7: Checking Commutator Mica Depth

   
8. Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature.
   Fig 8: Checking Continuity Between Segments Of Commutator

   
9. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
   Fig 9: Placing Armature On An Armature Tester

   
10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.
    Fig 10: Checking Continuity Between Commutator & Armature Coil Core And Between Commutator & Armature Shaft

    

    Starter Brush Inspection 

11. Measure the brush length. If it is not within the service limit, replace the armature housing assembly (M/T), or the brush holder assembly (A/T).

    Brush Length 

    Standard (New): 

    • M/T:  14.0-14.5 mm (0.55-0.57 in.)
    • A/T:  15.8-16.2 mm (0.62-0.64 in.)

    Service Limit: 

    • M/T:  9.0 mm (0.35 in.)
    • A/T:  11.0 mm (0.43 in.)
    Fig 11: Measuring Brush Length

    

    Starter Field Winding Test (M/T) 

12. Check for continuity between the brushes (A). If there is no continuity, replace the armature housing (B).
    Fig 12: Checking Continuity Between Brushes

    
13. Check for continuity between each brush (A) and the armature housing (B). If there is continuity, replace the armature housing.

    Starter Brush Holder Test 

14. Check that there is no continuity between the ( ) brush holder (A) and (-) brush holder (B). If there is no continuity, replace the brush holder assembly.
    Fig 13: Checking Continuity Between (+) Brush Holder & (-) Brush Holder (M/T)

    
    Fig 14: Checking Continuity Between (+) Brush Holder & (-) Brush Holder (A/T)

    
15. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush.

    Spring Tension: 

    • M/T:  13.7-17.7 N (1.4-1.8 kgf, 3.09-3.97 lbf)
    • A/T:  15.7-17.7 N (1.6-1.8 kgf, 3.53-3.97 lbf)
    Fig 15: Measuring Brush Spring Tension

    
16. Pry back each brush spring with a screwdriver, then position the brush about halfway out of its holder, and release the spring to hold it there.
    Fig 16: Installing Brush Spring

    
17. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and push the brush down until it seats against the commutator, then release the spring against the end of the brush.
    NOTE: To seat new brushes, slip a strip of 500 or 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.
    Fig 17: Installing Armature In Housing

    
18. Install the starter end cover (A) to retain the brush holder (B).
    Fig 18: Installing Starter End Cover

    

    Overrunning Clutch Inspection 

19. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
20. Rotate the overrunning clutch (A) both ways. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or it locks in both directions, replace it.
    Fig 19: Inspecting Overrunning Clutch (M/T)

    
    Fig 20: Inspecting Overrunning Clutch (A/T)

    
21. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.

    Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

22. Reassemble the starter in reverse order of disassembly.