Starter - 4-CYL: Overhaul: Reassembly

1. On diesel model starters, assemble armature and clutch as follows: Lubricate drive end of armature shaft with silicone lubricant and install center bearing, fiber washer and clutch assembly onto armature, with pinion away from armature. Slide retainer onto shaft and install snap ring and thrust washer.
   Fig 1: All Models - Checking Pinion-to-Housing Clearance Force gear rearward to eliminate slack.

   
2. Position retainer and thrust washer with snap ring in between. Using pliers, grip retainer and washer and squeeze until snap ring is forced into retainer and is held in groove in armature shaft.
3. On all models, lubricate drive gear housing bushing with silicone lubricant. Engage shift lever yoke with clutch and slide complete assembly into drive gear housing.
   Fig 2: Exploded View of Delco-Remy 27MT Starter Assembly. 5MT & 10MT starters similar except they have no center bearing.

   
4. Install center bearing screws and shift lever pivot bolt. Tighten securely. Install solenoid assembly on drive gear housing. Apply sealer (No. 1050026) to solenoid flange where it meets drive housing and field frame, using care not to damage brushes.
5. Position field frame against drive gear housing on alignment pin using care not to damage brushes. Lubricate commutator end frame bushing with silicone lubricant. Install washer on armature shaft and slide end frame onto shaft and install through bolts.
6. On diesel models, install insulator and then end frame onto shaft. Install through bolts, making sure they pass through bolt holes in insulator. Connect field coil connector to solenoid terminal. Check pinion clearance as outlined under, Parts Replacement and Testing in this article.

Fig 3: All Models - Exploded View of Shift Lever Assembly