Disassembly and Assembly

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
Assemble in the reverse order of disassembly. Do 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.

Grease:
ESSO BEACON 325
SHELL ALVANIA GREASE RA or equivalent

- Front and rear 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, make sure starter operates properly.