Starter Overhaul: Disassembly/Reassembly

Fig 1: Exploded View Of Starter With Torque Specifications

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Armature Inspection and Test 

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION ).
2. Disassemble the starter as shown in the Exploded View
3. Inspect the armature for wear or damage from contact with the permanent magnet If there is wear or damage, replace the armature.
   Fig 2: Identifying Armature

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4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 5, or recondition with #500 or #600 sandpaper (B).
   Fig 3: Checking Commutator Surface

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

   Commutator Diameter 

   Standard (New): 28.0-28.1 mm (1.102-1.106 in.) 

   Service Limit: 27.5 mm (1.083 in.) 

   Fig 4: Checking Commutator Diameter

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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 5: Measuring Commutator Runout

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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): 0.40-0 50 mm (0.016-0.020 in.) 

   Service Limit: 0.15 mm (0.006 in.) 

   Fig 6: Checking Commutator Mica Depth

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8. Check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature.
   Fig 7: Checking Continuity Between Segments Of Commutator

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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 8: Placing Armature On Armature Tester

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10. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
    Fig 9: Checking Continuity Between Commutator And Armature Coil Core

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    Starter Brush Inspection 

11. Measure the brush length If it is shorter than the service limit, replace the brush holder assembly.

    Brush Length 

    Standard (New): 11.1-11.5 mm (0.44-0.45 in.) 

    Service Limit: 4.3 mm (0.17 in.) 

    Fig 10: Measuring Brush Length

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    Starter Brush Holder Test 

12. Check for continuity between the (+) brushes (A) and (-) brushes (B) If there is continuity, replace the brush holder assembly
    Fig 11: Identifying Brush Holder Assembly

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    Planetary Gear Inspection 

13. Check the planetary gears (A) and internal ring gear (B). Replace them if they are worn or damaged.
    Fig 12: Identifying Planetary Gears And Internal Ring Gear

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    Overrunning Clutch Inspection 

14. While holding the drive gear (A), turn the gear shaft (B) counterclockwise Check that the drive gear comes out to the other end If the drive gear does not move smoothly, replace the gear cover assembly.
    Fig 13: Holding Drive Gear

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15. While holding the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaft does not turn freely, replace the gear cover assembly
16. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately

    Check the condition of the flywheel ring gear (M/T model) or the torque converter ring gear (A/T model) to see if the starter drive gear teeth are damaged.

    Starter Reassembly 

17. Install the brush into the brush holder, and set the armature (A) in the brush holder (B)
    NOTE: To seat the new brushes, slip a strip of # 500 or # 600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator
    Fig 14: Identifying Armature In Brush Holder

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18. While squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms Repeat this for the other three springs (D, E, and F).
19. Install the armature and brush holder assembly into the housing.
    NOTE: Make sure the armature stays in the holder