REMOVAL & INSTALLATION
- Disconnect the negative battery cable at the battery.
- Remove the starter-to-engine brace. On the four cylinder engine, there are two nuts securing the brace to the end of the starter; on the V6, there is one nut.
- Working under the car, remove the two starter-to-engine bolts, and allow the starter to drop down. Note the location and number of any shims.
- Label and disconnect the solenoid wires and battery cable. Remove the starter.
- Installation is the reverse of the removal procedure. Tighten the mounting bolts to 25-35 ft. lbs.
- Remove the screw and washer from the motor connector strap terminal.
- Remove the two screws which retain the solenoid housing to the end frame assembly.
- Twist the solenoid clockwise to remove the flange key from the keyway slot in the housing.
- Remove the solenoid assembly.
- With the solenoid return spring installed on the plunger, position the solenoid body on the drive housing and turn it counterclockwise to engage the flange key in the keyway slot.
- Install the two screws which retain the solenoid housing to the end frame.
- Disconnect the field coil straps from the solenoid.
- Remove the through bolts, and separate the commutator end frame, field frame assembly, drive housing, and armature assembly from each other.
- Slide the two piece thrust collar off the end of the armature shaft.
- Slide a suitably sized metal cylinder, such as a standard half-inch pipe coupling, or an old pinion, on the shaft so that the end of the coupling or pinion butts up against the edge of the pinion retainer.
- Support the lower end of the armature securely on a soft surface, such as a wooden block, and tap the end of the coupling or pinion, driving the retainer towards the armature end of the snapring.
- Remove the snapring from the groove in the armature shaft with a pair of pliers. Then, slide the retainer and starter drive from the shaft.
- Lubricate the drive end of the armature shaft with silicone lubricant, and then slide the starter drive onto the shaft with the pinion facing outward. Slide the retainer onto the shaft with cupped surface facing outward.
- Again support the armature on a soft surface, with the pinion at the upper end. Center the snapring on the top of the shaft (use a new snapring if the original was damaged during removal). Gently place a block of wood flat on top of the snapring so as not to move it from a centered position. Tap the wooden block with a hammer in order to force the snapring around the shaft. Then, slide the ring down into the snapring groove.
- Lay the armature down flat on the surface you're working on. Slide the retainer close up on to the shaft and position it and the thrust collar next to the snapring. Using two pairs of pliers on opposite sides of the shaft, squeeze the thrust collar and the retainer together until the snapring is forced into the retainer.
- Lube the drive housing bushing with a silicone lubricant. Then, install the armature and clutch assembly into the drive housing, engaging the solenoid shift lever with the clutch, and positioning the front end of armature shaft into the bushing.
- Apply a sealing compound approved for this application onto the drive housing; then position the field frame around the armature shaft and against the drive housing. Work slowly and carefully to prevent damaging the starter brushes.
- Lubricate the bushing in the commutator end frame with a silicone lubricant, place the leather brake washer onto the armature shaft, and then slide the commutator end frame over the shaft and into position against the field frame. Line up the bolt holes, and then install and tighten the through bolts.
- Reconnect the field coil straps to the "motor" terminal of the solenoid.
If replacement of the starter drive fails to cure the improper engagement of the starter pinion to the flywheel, there are probably defective parts in the solenoid and/or shift lever. The best procedure would probably be to take the assembly to a shop where a pinion clearance check can be made by energizing the solenoid on a test bench. If the pinion clearance is incorrect, disassemble the solenoid and the shift lever, inspect, and replace worn parts.Brush Replacement
- After removing the starter from the engine, disconnect the field coil from the motor solenoid terminal.
- Remove the starter thru-bolts and remove the commutator end frame and washer.
- Remove the field frame and the armature assembly from the drive housing.
- Remove the brush holder pivot pin which positions one insulated and one grounded brush.
- Remove the brush springs.
- Remove the brushes.
- Installation is the reverse of the removal procedure.