Disassembly and Assembly

Dial Indicator With Bracketry:

SPECIAL TOOLS






DISASSEMBLY






1. Remove the (A) starter solenoid M-terminal nut and the (B) starter motor brush holder cable.






2. Remove the two (A) solenoid bolts and the (B) starter solenoid.






3. Remove the two (A) through bolts, the (B) brush end plate and bushing and the (C) brush holder.






4. Remove the two (A) brush plate bolts and separate the (B) brush holder from the (C) brush end plate and bushing.
5. Mark the brushes for position.

NOTE: Brushes must be marked for position before removal.






6. Remove the brushes from the brush holder.
1. Remove the four brush springs.
2. Remove the four brushes.






7. Remove the (A) bushing from the (B) brush end plate.






8. Remove the (A) starter motor armature from the (B) starter frame and magnet.






9. Remove the (A) E-ring and the (B) pinion thrust washer from the (C) output shaft.






10. Separate the (A) stationary gear from the (B) output shaft.






11. Separate the (A) output shaft from the (B) starter motor armature and remove the (C) armature thrust ball.

CAUTION: Do not lose the armature thrust ball.






12. Remove the (A) planet gear retainer and the three (B) planet gears from the (C) output shaft.






13. Disassemble the starter motor drive end.
^ Remove the (A) seal, the (B) drive lever and pin, and the (C) starter drive.






14. Remove the (A) starter drive stop ring and the (B) stop ring retainer.






15. Remove the (A) bushing from the (B) drive end housing.






16. Clean the starter motor parts. Use a brush or dry cloth only to clean (A) damageable parts. Use solvent to clean (B) other parts.

CAUTION: Cleaning solvent may damage certain starter motor parts.






17. Inspect the starter motor armature for signs of overheating.






18. Use Dial Indicator With Bracketry to inspect the starter motor armature commutator for runout and roughness.
^ If commutator is rough, or more than 0.12 mm (0.005 inch) out of round, it must be replaced.






19. Use Dial Indicator With Bracketry to inspect the starter motor armature shaft for runout.
^ If the starter armature is not within specification, it must be replaced.






20. Inspect the (A) brushes for length and the (B) brush springs for proper tension. Make sure that the brushes slide easily in the (C) brush holder.

ASSEMBLY






1. Soak the two (A) bushings for 20 minutes in 20W engine oil Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B and install them in the (B) brush end plate and the (C) drive end housing.






2. Lubricate the (A) starter motor armature at each end with 20W Synclolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B. Install the starter motor armature into the (B) starter frame.






3. Install the (A) brush set and the four (B) brush springs in the (C) brush holder.






4. Install the brush holder.

NOTE: Make sure the brushes are on top of the commutator.






5. Position the (A) brush end plate and bushing and install the two (B) brush plate bolts.






6. Lubricate the (A) output shaft spline with 20W Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B and install the (B) stationary gear, the (C) pinion thrust washer, and the (D) E-ring.






7. Install the (A) starter drive on the (B) output shaft. Install the (C) starter drive stop ring and the (D) stop ring retainer onto the end of the starter drive output shaft.






8. Connect the (A) drive lever and pin to the (B) starter drive.






9. Lubricate and install the (A) planet gears on the (B) output shaft and install the (C) planet gear retainer and the (D) armature thrust ball.
^ Use 20W Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.






10. Lubricate the (A) starter drive bore. Install the (B) starter drive assembly and the (C) seal.
^ Use 20W Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B.






11. Position the (A) starter frame assembly on the (B) drive end housing and install the two (C) through bolts.






12. Position the (A) starter solenoid on the (B) starter motor and install the two (C) solenoid bolts.






13. Position the (A) starter motor brush holder cable on the (B) starter solenoid M-terminal and install the (C) starter solenoid M-terminal nut.