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Pinion Gap Adjustment Test

  1. Disconnect field lead from terminal "M" of solenoid to prevent starter from turning. See Fig 1. Connect jumper wire from a 12-volt battery positive terminal to terminal "S" of solenoid. Connect another jumper wire from negative battery terminal to terminal "M" of solenoid.
  2. Solenoid should energize when battery is connected, kicking out drive pinion. With drive pinion extended, measure pinion gap between drive pinion and collar. Gap should be .020-.080" (.5-2.0 mm). See Fig 1.
    NOTE: DO NOT engage solenoid for more than 10 seconds. If test must be repeated, wait at least 3 minutes between tests to allow solenoid to cool.
  3. Add or subtract shims between solenoid and end housing to achieve proper pinion depth gap. Install field lead to terminal "M" of solenoid. Install nut and tighten to 70-106 INCH lbs. (8-12 N.m).
Fig 1: Measuring Pinion Gap
G90C08870Courtesy of FORD MOTOR CO.
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