Overhaul

Starter Overhaul

A/T model

Exploded View





Brush Holder Removal

Note: Refer to the Exploded View if needed during this procedure.

1. Remove the starter Removal and Replacement.

2. Disconnect the motor wire from M terminal, and remove the end cover.

3. Pry back each brush spring with a screwdriver, then position the brush on the brush holder about halfway out of its holder. Release the spring to hold it in place.

4. Remove the brush holder assembly (A).






Armature Inspection and Test

5. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.






6. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 7, or recondition with #500 or #600 sandpaper (B).






7. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.










8. Measure the commutator (A) runout.

- If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
- If the commutator runout is not within the service limit, replace the armature.










9. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.










10. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.






11. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.






12. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.






Overrunning Clutch Inspection

13. Slide the overrunning clutch (A) along the shaft.
Replace it if it does not slide smoothly.






14. Hold the overrunning clutch (A), and turn the drive gear (B) in the direction shown to make sure it turns freely. Also make sure the drive gear locks in the opposite direction. If it does not lock, replace the overrunning clutch assembly.





15. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the torque converter ring gear to see it if the starter drive gear teeth are damaged.

Starter Brush Inspection

16. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.










Starter Brush Holder Test

17. Check for continuity between the (1-2) brush holders (A) and the (3-4) brush holders (B). If there is continuity, replace the brush holder assembly.






Brush Spring Inspection

18. Insert the brush (A) into the brush holder, and bring the brush into contact with the commutator, then attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. If it is not within the standard, replace the brush holder assembly.










Planetary Gear Inspection

19. Check the planetary gears (A), the armature shaft gear (B), and the internal ring gear (C). Replace them if they are worn or damaged.






Starter Reassembly

20. Install the armature housing (A) and the armature (B) by aligning the slotted point (C) to the projection (D).






21. Pry back each brush spring with a screwdriver, then position the brush on the brush holder about halfway out of its holder. Release the spring to hold it in place.

NOTE: To seat the new brushes. Slip a strip of #500 or #600 sandpaper, with the grit side up, between the commutator and the each brush, and smoothly turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.






22. Install the brush holder assembly. Next pry back each brush spring again, and push each brush down until it seats against the commutator, then release the spring against the end of the brush.






23. Install the end cover to retain the brush holder.





24. Install the starter.