Starters - Gear Reduction: Overhaul: Disassembly
- Remove through bolts and end plate. Carefully pull armature up and out. Remove steel and fiber thrust washer.NOTE: Shunt field coil wire is wrapped on brush terminal. One set of brushes is connected to this terminal, other set of brushes is attached to series field coils by a terminal screw. Carefully pull frame and field assembly up just enough to expose screw and solder connection at brush terminal. Place two wood blocks between frame and gear housing to aid removal of screw.
- Remove terminal screw and unwrap shunt field coil lead from brush terminal.NOTE: Brush holder plate with brush terminal, contact and brushes is serviced as an assembly.
Unwrap solenoid lead wire and unwind wire from brush terminal. Remove nut, steel washer and insulating washer from solenoid terminal. Straighten solenoid wire and remove brush holder plate with brushes and solenoid as an assembly. Remove solenoid assembly from gear housing well.
- Remove following (in sequence); nut from starter battery terminal, starter battery terminal from holder plate, solenoid contact and plunger from solenoid, solenoid return spring from well of solenoid housing moving core, dust cover from gear housing. Release retainer clip that positions driven gear on pinion shaft.CAUTION: Retainer is under tension.
Release retainer ring at front of pinion shaft.
NOTE: Do not spread ring greater than outside diameter of shaft or ring will be damaged. - Push pinion shaft towards rear of housing, remove retainer ring and thrust washers, clutch and pinion assembly (with 2 shift fork nylon actuators as an assembly). Remove driven gear and friction washer. Pull shifting fork forward and remove solenoid moving core. Remove shifting fork retainer pin and remove clutch shifting fork assembly.