Starter Assembly

1. Starter drive to armature shaft as follows:
A. Apply a small amount of lubricant (GM P/N 1960954) to the armature shaft to starter drive contact points.
B. Drive onto armature shaft with the pinion gear away from the armature.
C. Pinion stop collar onto armature shaft.
D. New pinion stop retainer ring into groove on shaft.
E. Thrust collar to end of shaft with small flange toward retainer ring. Use pliers to snap pinion stop collar over retainer ring.
2. Fit shift lever yoke to drive collar, then armature drive lever into the Drive End (DE) housing.
3. Shift lever shaft through holes in DE housing and shift lever, then secure with retainer. Place the solenoid return spring onto the solenoid plunger.

NOTE: Use only GM P/N 10477431 grease to lubricate solenoid core. This grease is specially formulated to aid plunger movement and dampen vibration of plunger as engine runs. Other greases may eventually degrade and prevent proper plunger movement, causing starter failure.

4. Lubricate solenoid core. Apply one complete packet (1 gram) of GM P/N 10477431 grease evenly around inside edge of the solenoid core. Apply all grease thickly to the first 13 mm (0.5 inch) inside the edge of the core. Plunger movement will distribute grease properly. Avoid getting dirt or other contamination in grease before installing solenoid to starter.
5. Solenoid over plunger by compressing spring, rotating solenoid 90 degrees to install to housing. Install the starter solenoid to starter motor, bolts/screws.
Tighten
^ Bolts/screws to 6.5 N.m lb.58 lb. in.).
6. Frame and field as follows:
A. Apply sealer (GM P/N 1050026 or equivalent) on the solenoid flange to frame and field contact points.
B. Push brushes into supports and holds.
C. Install frame and field over armature, aligning properly to DE housing.
D. Release brushes onto commutator. Be sure that all four brushes move freely in their respective holders. Insure that all four brushes make contact with the commutator.
7. Brake washer onto armature shaft.
8. Commutator End (CE) frame onto armature shaft, aligning with frame and field.
9. Identification tag onto thru-bolt, then starter motor thru-bolts to starter motor as noted during disassembly.
Tighten
^ Bolts/screws to 8.5 N.m (75 lb. in.).
10. Perform the "Pinion Clearance Check". If the pinion clearance is within specifications, connect the starter motor field lead to the starter motor solenoid terminal.
11. Starter solenoid to field terminal bolt/screw.
Tighten
^ Bolt/screw to 7.3 N.m (65 lb. in.).
12. Install the starter motor.