Starters - Gear Reduction: Overhaul: Reassembly
- Make sure shift fork plates have approximately 1/16" side movement, lubricate sparingly between plates with SAE 10 engine oil. Position shift fork in housing bending one tip of pin at 15° angle away from housing.NOTE: Fork and pin must operate freely.
Install solenoid moving core and engage shifting fork.
- Start pinion shaft into drive housing, install friction washer and drive gear, clutch and pinion assembly, thrust washer, retaining ring and thrust washer. Make sure shift fork engages clutch actuators properly.NOTE: Friction washer must be positioned on shoulder of splines of pinion shaft before driven gear is positioned.
Install driven gear snap ring, pinion shaft retaining ring, starter solenoid return spring into bore of movable core.
- Install solenoid contact plunger assembly into solenoid and reform double wires to allow for proper entry of terminal stud into brush holder with double wires curved around contactor.CAUTION: Contactor must not touch wires when solenoid is energized after assembly.
Assemble battery terminal stud in brush holder. Position seal on brush holder plate.
- Start solenoid lead wire through hole in brush holder, install solenoid stud, insulating washer, flat washer and nut. Wrap lead wire tightly around brush terminal post, solder with high temperature resin core solder and resin flux. Install brush holder to solenoid attaching screws. Enter solenoid coil and brush plate assembly into starter gear housing, install and tighten attaching nuts.
- Install armature thrust washer in brushes with brushes resting on washer tabs (washer will hold brushes out and facilitate armature installation). Solder shunt coil lead wire to starter brush terminal. Install brush terminal screw.
- Place field frame in exact correct position on gear housing, enter armature into field frame and gear housing being careful to pickup thrust washer installed in starter brushes, engage shaft teeth with reduction gear by rotating armature as necessary. Install fiber thrust washer and steel washer on end of armature shaft, position end head assembly on field frame and install through bolts and lock-washers, tighten bolts securely.