Operation CHARM: Car repair manuals for everyone.

Disassembly and Assembly

SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Impact Slide Hammer 100-001 (T50T-100-A)







DISASSEMBLY
1. Remove the M-terminal nut securing the brush cable to the starter solenoid.
2. Remove the two starter solenoid screws from the drive end housing.
3. Remove the starter solenoid and the two adjusting plates from the drive end housing.
4. Remove the plunger and plunger spring from the starter solenoid.
5. Remove the dust cover and disc plate from the drive end housing.
6. Remove the nut and support bracket.
7. Remove the two thru bolts.
8. Remove the two brush holder screws securing the brush holder to the brush end plate.
9. Remove the brush end plate.
10. Remove the brush holder and brush spring assembly.
11. Remove the starter motor armature and starter frame from the drive end housing.
12. Remove the ball bearing.
13. Remove the starter motor armature from the starter frame.
14. Remove the three planet gears from the output shaft.
15. Remove the packing from the internal gear.
16. Remove the dust cap.
17. Insert the starter motor armature into the output shaft.







18. Use a socket and hammer and drive down the stop ring retainer to release the stop ring.







19. Use a screwdriver to remove the stop ring.
20. Remove the stop ring retainer, pinion drive gear and pinion drive gear spring.
21. Remove the starter motor armature from the output shaft.
22. Remove the starter drive, internal gear and output shaft assembly.
23. Remove the drive lever and pin.
24. Use a socket and hammer and drive down the stop ring retainer and release the stop ring.
25. Remove the stop ring.
26. Remove the stop ring retainer.
27. Separate the starter drive, output shaft and internal gear.







28. Use Blind Hole Puller Set 303-DS005 (D80L-100-A) or equivalent, and Impact Slide Hammer 100-001 (T50T-100-A) to remove the bearing from the drive end housing.

ASSEMBLY
1. Use a soft punch and a hammer and seat the bearing into the drive end housing.

NOTE: Apply grease to the inner sleeve of the bearing before installation.

2. Install the internal gear on the output shaft.
3. Install the starter drive on the output shaft.
4. Install the stop ring retainer onto the output shaft.
5. Install the stop ring onto the output shaft.
6. Use a soft punch and hammer to drive on the end of the output shaft to seat the stop ring in the stop ring retainer.
7. Install the internal gear, starter drive, output shaft, and drive lever and pin in the drive end housing.

NOTE: Apply grease to the drive lever and pin prior to installation.

8. Install the starter motor armature into the output shaft.
9. Install the pinion drive gear spring, pinion drive gear and stop ring retainer onto the starter drive.
10. Install the stop ring.
11. Remove the starter motor armature.







12. Insert a screwdriver between the pinion drive gear and the stop ring retainer to seat the stop ring.
13. Install the ball bearing.
14. Install the planet gears.

NOTE: Apply grease to the planet gears and the mounting points prior to installation.

15. Install the packing.
16. Install the starter motor armature in the starter frame.
17. Install the starter motor armature and starter frame into the drive end housing.
18. Install the brush holder and brush spring assembly on the starter motor armature.
19. Install the brush end plate. Install the two brush holder screws securing the brush holder to the brush end plate. Tighten the brush holder screws to 2.0-2.9 Nm (18-26 Lb-In).
20. Install the two thru bolts. Tighten the thru bolts to 6.9-8.8 Nm (61-78 Lb-In).
21. Install the disc plate and dust cover.
22. Install the plunger and plunger spring into the starter solenoid.
23. Install the starter solenoid into the drive end housing. Install the two starter solenoid screws. Tighten the starter solenoid screws to 4.9-6.9 Nm (43-61 Lb-In).
24. Install the brush cable and the M-terminal nut. Tighten the M-terminal nut to 9.8-11.8 Nm (87-104 Lb-In).
25. Install the support bracket and nut.
26. Install the dust cap.