Starter - Gasoline Models: Overhaul: Reassembly

Fig 1: Exploded View of Motorcraft Starter Motor Assembly

1. Position coils and pole pieces (with coil leads in terminal screw slot), install retaining screws. As screws are tightened, strike frame several times with soft faced hammer to seat and align pole shoes. Stake screws after fully tightened.
2. Install plunger coil sleeve and retainer, bend tabs to retain coils to frame. Position grommet on end terminal and align into notch in frame. Using a 300 watt soldering iron and rosin core solder, solder field coil to starter switch terminal post.
3. Check for continuity and grounds in assembled coils. Position the ground brushes to starter frame and install retaining screws. Apply a thin coat of Lubriplate 777 (or equivalent) on armature shaft splines. Install starter motor drive gear assembly to armature shaft, new stop ring, stop ring retainer, and thrust washer.
4. Install armature in starter frame. Position the starter drive gear plunger lever to frame and starter drive assembly. Install pivot pin. Fill drive end housing bearing 1/4 full with grease. Position drive end housing to frame making sure lever return spring engages tang on lever.
5. Install brush holder, brushes, and springs. Positive brush leads should be positioned in their respective slots to prevent potential grounding. Install brush end plate. Ensure that end plate insulator is positioned properly on end plate.
6. Install through bolts to starter frame and tighten to 55-75 INCH lbs (6-8 N.m). Install starter drive plunger lever cover and tighten retaining screw. Check starter no-load current draw. It should be 80-85 amps.

MOTORCRAFT STARTER SPECIFICATIONS

Application		Specification
Load Test Current Draw
4" Frame		150-250 Amps
4 1/2" Frame		150-210 Amps
No-Load Test Current Draw
4" Frame		80 Amps
4 1/2" Frame		85 Amps
Brush Length
Original		.45" (11.4 mm)
Maximum Wear Length		.25" (6.4 mm)
Brush Spring Tension		80 oz.
Through Bolt
Tightening Torque		45-85 INCH Lbs. (5.0-9.6 N.m)