Starting System & Charging System (H4DO): Starter: Disassembly

Disconnect the terminal M from the magnet switch assembly.

Fig 1: Locating Magnet Switch Assembly Terminal
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Remove the magnet switch assembly from the starter housing assembly.

Fig 2: Locating Magnet Switch Assembly Bolts
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Remove screws (A) and bolts (B) of the brush holder assembly, and remove the starter cover assembly.

Fig 3: Identifying Brush Holder Assembly Screws And Bolts
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Remove the brush holder assembly from the armature assembly.
NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.

Fig 4: Holding Brush With Fingers
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Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.

Fig 5: Identifying Starter Housing
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Separate the armature assembly and yoke assembly.

Fig 6: Removing Armature And Yoke Assembly
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Remove the pinion gear from the internal gear assembly.

Fig 7: Identifying Internal Gear Assembly Pinion Gear
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Remove seal rubber (A), plate (B), and seal rubber (C).

Fig 8: Removing Seal Rubber
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Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one unit.

Fig 9: Tapping Starter Housing Assembly With Plastic Hammer
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Use the following procedures to remove the overrunning clutch from the shaft.
1. Use an appropriate tool (such as a fit socket wrench), and remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer.
  
  Fig 10: Removing Stopper From Snap Ring With Plastic Hammer
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove snap ring (A) from the shaft, and remove stopper (B).
  
  Fig 11: Removing Snap Ring From Shaft
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3. Remove the overrunning clutch from the shaft.
  
  Fig 12: Removing Overrunning Clutch From Shaft
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Separate the internal gear assembly and shaft.

Fig 13: Disassembling Internal Gear Assembly And Shaft
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