Starter Motor: Service and Repair

REMOVAL AND INSTALLATION




1. Disconnect battery ground cable.
2. Remove air intake chamber.




3. Disconnect connector and terminal from starter.
4. Remove starter from transmission.
5. Installation is in the reverse order of removal.

Tightening torque:
50 ± 4 N.m (5.1 ± 0.4 kg-m, 37 ± 2.9 ft-lb)

DISASSEMBLY




1. Loosen nut which holds terminal M of switch assembly, and disconnect connector.
2. Remove bolts which hold switch assembly, and remove switch assembly, plunger and plunger spring from starter as a unit.

CAUTION: Be careful because pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.




3. Remove both through-bolts and brush holder screws, and detach rear bracket and brush holder.




4. Remove armature and yoke. Ball used as a bearing will then be removed from the end of armature.

CAUTION: Be sure to mark an alignment mark on yoke and front bracket before removing yoke.




5. Remove packing A, three planetary gears, packing B and plate.




6. Remove shaft assembly and overrunning clutch as a unit.

CAUTION: Record the direction of lever before removing.




7. Remove overrunning clutch from shaft assembly as follows:
1. Remove stopper from ring by lightly tapping a fit tool placed on stopper.
2. Remove ring, stopper and clutch from shaft.

ASSEMBLY

Assembly is in the reverse order of disassembly procedures. Observe the following:
1. Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been overlooked.
2. Apply grease to the following parts during assembly.
- Front bracket sleeve bearing
- Armature shaft gear
- Outer periphery of plunger
- Mating surface of plunger and lever
- Gear shaft splines
- Mating surface of lever and clutch
- Ball at the armature shaft end
- Internal and planetary gears

3. After assembling parts correctly, check to be sure starter operates properly.