Starter Motor Unit Assembly

1. Support the gear reduction and drive group.
2. Place the pinion gear end down.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Use the following procedure in order to install the solenoid assembly:
3.1. Pivot the plunger of the solenoid assembly in order to engage the plunger to the shift lever in the gear reduction and drive group.
3.2. Position the solenoid mounting flange.
3.3. Install the solenoid mounting screws.

Tighten
Tighten the solenoid screws to 2.8 N.m (25 lb in).

4. Install the frame seal.

IMPORTANT: If you are replacing the armature bearings, install the bearings onto the armature. Refer to Armature Bearing Replacement.

5. Use the following procedure in order to install the armature assembly and the bearings into the gear reduction and drive group.
5.1. Ensure that the teeth align.
5.2. Seat the bearing on the armature shaft fully into the housing recess.
6. Use the following procedure in order to install the frame the field and the brush holder group.
6.1. Place the dowel pin into the hole in the armature support bracket of the gear reduction and drive group.
6.2. Position the frame the field and the brush holder group over the armature assembly.
6.3. Align the hole for the dowel pin.
6.4. Align the marks made during disassembly.
6.5. Seat the frame the field and the brush holder group into the gear reduction and drive group.
6.6. Twist the brush springs away from the brushes.
6.7. Slide the brushes in order to contact the commutator on the armature.
6.8. Release the brush springs in order to contact the ends of the brushes.
6.9. Verify that the brush spring tension is 44.5-49 N.m (10-11 lb).
6.10 If the brush spring tension is not correct, replace the brush springs.

IMPORTANT: The O-ring seal will damage easily during installation of the commutator end frame. In order to prevent damage to the O-ring seal, use the following procedure.

7. Use the following procedure in order to install the O-ring seal.
7.1. Install the O-ring seal onto the frame, field and brush holder group in the normal position. The O-ring seal is in the normal position when the seal is against the shoulder on the field frame that will abut the installed commutator end frame.
7.2. Carefully roll the O-ring seal out of the normal position and up onto the major outer diameter of the field frame.
7.3. Allow the seal to remain on the outer diameter of the field frame until the commutator end frame is partially installed.






8. Use the following procedure in order to install the commutator end frame.
8.1. Align the marks on the commutator end frame and the frame and field assembly made at disassembly.
8.2. Position the commutator end frame onto the frame and field assembly.
8.3. Leave a gap slightly larger than the thickness of the O-ring seal.






9. Use the following procedure in order to install the brush plate screws.
9.1. Use a scribe or a similar tool in order to align the tapped holes in the brush holder assembly to the screw holes in the commutator end frame.
9.2. Install the brush plate screws.

Tighten
Tighten the brush plate screws to 2.8 N.m (25 lb in).






10. Use the following procedure in order to install the through-bolts.
10.1. Position the through-bolts.
10.2. Tighten the through-bolts by hand, but do not close the gap between the commutator end frame and the frame and field assembly where the O-ring seal will be located.
10.3. Roll the O-ring seal down into the normal position. The normal position is between the commutator end frame and the frame and field assembly.
10.4. Align the timing ribs on the edge of the commutator end frame to the timing spots on the frame and field assembly in order to ensure proper alignment of the brushes.
10.5. Although the marks are located in 2 places on the motor, the marks will only match in 1 way.

Tighten
Tighten the through-bolts to 8.5 N.m (75 lb in).






11. Use the following procedure in order to install the motor lead onto the frame and field assembly.
11.1. Remove the nut from the terminal on the solenoid.
11.2. Install the motor lead terminal.
11.3. Reinstall the solenoid motor terminal nut.

Tighten
Tighten the solenoid motor terminal nut to 11 N.m (100 lb in).