Chrysler Full-Size Trucks 1967-1988 Repair Guide

Starter

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Almost all models are equipped with a reduction gear type starter motor. The only exception are some 1967 models with the 8-318. In 1967, a few models came equipped with a direct drive starter motor because of a higher compression ratio in some 318 V8's.

The diesel uses a reduction gear starter which differs slightly from the regular unit, having a 3.75:1 ratio as compared to a 3.5:1 ratio.



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Fig. Fig. 1: Direct Drive Starter Diagnosis



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Fig. Fig. 2: Reduction Drive Starter Diagnosis

TESTING



Bench Test
GASOLINE ENGINES
  1. Remove starter from vehicle.
  2.  
  3. Place starter in a soft jawed vise and position a fully charged, 12-volt battery so it can be connected to the starter.
  4.  
  5. Connect a test ammeter (100 amp scale) and a carbon pile rheostat in series with battery positive post and starter terminal.
  6.  
  7. Connect a voltmeter (15 volt scale) across starter from starter battery terminal to ground.
  8.  
  9. Rotate the carbon pile to full-resistance position.
  10.  
  11. Connect the battery cable from battery negative post to starter frame.
  12.  
  13. Adjust rheostat until battery voltage shown on voltmeter reads 11 volts.
  14.  
  15. With the starter engaged, check the specifications for maximum amperage draw and minimum RPM's At 11 volts, the allowable amperage draw is approximately 90 amps, while the allowable minimum RPM rate is around 3700 RPM's. If either of these specifications are not within range, the starter should be replaced or rebuilt..
  16.  

DIESEL ENGINES
  1. Remove starter from vehicle.
  2.  
  3. Place starter in a soft jawed vise and position a fully charged, 12-volt battery so it can be connected to the starter.
  4.  
  5. Connect a test ammeter (250 amp scale) and a carbon pile rheostat in series with battery positive post and starter terminal.
  6.  
  7. Connect a voltmeter (15 volt scale) across starter from starter battery terminal to ground.
  8.  
  9. Rotate the carbon pile to full-resistance position.
  10.  
  11. Connect the battery cable from battery negative post to starter frame.
  12.  
  13. Adjust rheostat until battery voltage shown on voltmeter reads 11 volts. Read the amperage draw on the ammeter, draw should be 180 amps or less.
  14.  

REMOVAL & INSTALLATION



Gasoline Engines

See Figures 3 through 7

  1. Disconnect the ground cable at the battery.
  2.  
  3. Remove the cable from the starter.
  4.  



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Fig. Fig. 3: The starter is usually easiest to access from under the vehicle

  1. Disconnect the solenoid leads at their solenoid terminals.
  2.  



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Fig. Fig. 4: Disconnect the battery cable from the solenoid terminal



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Fig. Fig. 5: Remove all solenoid wire leads

  1. Remove the starter attachment bolts and withdraw the starter from the engine flywheel housing. On some models with automatic transmissions, the oil cooler tube bracket will interfere with the starter removal. In this case, remove the starter attachment bolts, slide the cooler tube bracket off the stud, and then withdraw the starter.
  2.  



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Fig. Fig. 6: On automatic transmissions you may need to unbolt the oil cooler lines or bracket



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Fig. Fig. 7: Carefully remove starter, don't drop it as your head will be needed later

To install:
  1. Be sure that the starter and flywheel housing mating surfaces are free of dirt and oil to make a good electrical contact.
  2.  
  3. Slide the starter in place, secure using the bolts and washers removed. Connect wires and battery cable end at the starter.
  4.  
  5. Secure the oil cooler bracket if equipped. Connect the negative battery cable on the battery.
  6.  

When tightening the mounting bolt and nut on the starter, hold the starter away from the engine for the correct alignment.

Diesel Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Raise the truck and support it safely on jackstands.
  4.  
  5. Disconnect and label the wires at the starter motor.
  6.  
  7. Remove the attaching bolt, nut and washer, then lift the starter and solenoid assembly from the engine.
  8.  

To install:
  1. Before installing the starter motor, be sure the mounting surface on the drive end housing and the flywheel housing are clean, to ensure good electrical contact. When tightening the attaching bolt and nut, hold the starter away from the engine to ensure the proper alignment.
  2.  
  3. Attach the wiring at the starter.
  4.  
  5. Attach the negative battery cable.
  6.  

SOLENOID & BRUSH REPLACEMENT



You will need to purchase new brushes and a solenoid before proceeding on this job.

Reduction Gear Starter

See Figure 8

  1. Disconnect the ground cable at the battery.
  2.  
  3. Remove the cable from the starter.
  4.  



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Fig. Fig. 8: Common brush mounting

  1. Remove the starter from the truck and support the starter gear housing in a vise fitted with soft jaws. Do not clamp.
  2.  
  3. Remove the two through-bolts and the starter end assembly.
  4.  
  5. Carefully pull the armature up and out of the gear housing and the starter frame field assembly.
  6.  
  7. Carefully pull the frame and field assembly up just enough to expose the terminal screw (which connects the series field coils to one pair of motor brushes) and support it with two blocks.
  8.  
  9. Support the terminal by placing a finger behind it and remove the terminal screw.
  10.  
  11. Unwrap the shunt field coil lead from the other starter brush terminal. Unwrap the solenoid lead wire from the brush terminal.
  12.  
  13. Remove the steel and fiber thrust washer.
  14.  
  15. Remove the nut, steel washer, and insulating washer from the solenoid terminal.
  16.  
  17. Straighten the solenoid wire and remove the brush holder plate with the brushes and solenoid as an assembly.
  18.  


WARNING
Do not break the shunt field wire units when removing and installing the brushes.

  1. Inspect the starter brushes. Brushes which are worn more than one-half the length of new brushes, or are oil-soaked, should be replaced.
  2.  

When resoldering the shunt field and solenoid leads, make a strong, low-resistance connection using a high-temperature solder and resin flux.

  1. Assemble the brush holder plate with the brushes and solenoid.
  2.  
  3. Install the nut, steel washer, and insulating washer on the solenoid terminal.
  4.  
  5. Install the steel and fiber thrust washer.
  6.  
  7. Wrap the shunt field coil lead around the other starter brush terminal. Wrap the solenoid lead wire around the brush terminal.
  8.  
  9. Install the terminal screw which connects the series field coils to one pair of motor brushes.
  10.  
  11. Carefully push the armature down into the gear housing and the starter frame field assembly.
  12.  
  13. Install the starter end assembly and the two through-bolts.
  14.  
  15. Install the starter.
  16.  

Direct Drive Starter

See Figure 9

  1. Remove the starter from the truck and support it in a vise fitted with soft jaws. Do not clamp.
  2.  
  3. Remove the through-bolts and tap the commutator and head from the field frame.
  4.  
  5. Remove the thrust washers from the armature shaft.
  6.  
  7. Lift the brush holder springs and remove the brushes from the holders. Remove the brush plate.
  8.  
  9. Disconnect the field coil leads at the solenoid connector.
  10.  
  11. Inspect the starter brushes. Brushes that are worn more than one-half the length of new brushes, or are oil-soaked, should be replaced. To replace the brushes, continue this procedure.
  12.  
  13. Remove the ground brush terminal screw and carefully remove the ground brush set to prevent breaking the shunt field lead. Remove the shunt field lead from the old brush set to ensure as much length as possible.
  14.  



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Fig. Fig. 9: Replacement of brushes on 1967 direct drive starter

  1. Remove the field terminal plastic covering and remove the old brushes. Use side cutters to break the weld by rolling the stranded wire off the terminal.
  2.  
  3. Drill a 0.174-0.184 in. (4.41-4.67mm) hole in the series coil terminal 3 / 16 in. (4.7mm) from the top of the terminal to the centerline of the hole (use a number 16 drill).
  4.  


WARNING
Do not damage the field coil during the drilling operation.

  1. Attach the insulated brush set to the series field terminal with a flat washer and a number 8 self-tapping screw. Attach the shunt field lead to the new ground brush set by making a loop around the terminal and soldering the lead to the terminal with resin core solder.
  2.  
  3. Attach the ground brush terminal to the field frame with the attachment screw. Fold the extra shunt field lead back along the brush lead and secure it with electrical tape.
  4.  
  5. Connect the field coil leads at the solenoid connector.
  6.  
  7. Install the plate and the brushes in the brush holders.
  8.  
  9. Install the thrust washers on the armature shaft.
  10.  
  11. Install the armature.
  12.  
  13. Install the field frame and through-bolts.
  14.  
  15. Install the starter.
  16.  

OVERHAUL



1967 Chrysler Direct Drive Starter
  1. Remove the through-bolts and tap the commutator end frame from the field frame.
  2.  
  3. Remove the thrust washers from the armature shaft.
  4.  
  5. Lift the brush holder springs and remove the brushes.
  6.  
  7. Remove the brush plate.
  8.  
  9. Disconnect the field coil leads at the solenoid connector.
  10.  
  11. Remove the solenoid attaching screws, then remove the solenoid and boot.
  12.  
  13. Drive out the overrunning clutch shift fork pivot pin.
  14.  
  15. Remove the drive end pinion housing and spacer washer.
  16.  

If the rubber seal is damaged, the pinion housing will have to be replaced.

  1. Note the position of the shifter fork on the starter drive and remove the fork.
  2.  
  3. Slide the overrunning clutch pinion gear towards the commutator end of the armature.
  4.  
  5. Slide the drive stop retainer toward the clutch pinion gear to expose the snapring and remove the snapring.
  6.  
  7. Slide the overrunning clutch drive from the armature shaft.
  8.  
  9. If it is necessary to replace the field coils, remove the ground brush terminal attaching screw and raise the brush with the terminal and shunt wire up and out of the way. Remove the pole shoe screws with an impact screwdriver.
  10.  
  11. When assembling the starter, lubricate the armature shaft and splines with 10W-30 engine oil.
  12.  

  1. Install the starter drive, stop-collar, lockring and spacer.
  2.  
  3. Install the shifter fork over the starter drive spring retainer washer with the narrow leg of the fork towards the commentator. THIS IS IMPORTANT! If the fork is not properly positioned, the starter gear travel will be restricted causing a lockup in the drive mechanism.
  4.  
  5. Install the drive end pinion housing, indexing the the shifting fork with the slot in the drive end housing.
  6.  
  7. Install the shifter fork pivot pin.
  8.  
  9. Slide the armature into the field frame until the pinion housing indexes with the slot in the field frame.
  10.  
  11. Install the solenoid and boot, then torque the bolts to 60-70 inch lbs. (6.7-7.8 Nm).
  12.  
  13. Connect the field coil leads at the solenoid connector.
  14.  

Make sure that the terminals do not touch the field frame!

  1. Install the brush holder ring, indexing the tang on the ring with the hole in the field frame.
  2.  
  3. Position the brushes in the holders. Make sure that the field coil lead wires are properly positioned behind the holder plate to avoid interference with the brush operation.
  4.  
  5. Install the thrust washers on the commutator to establish an end-play of 0.010 in. (0.25mm) minimum.
  6.  
  7. Install the commutator end head.
  8.  
  9. Install the through-bolts and torque them to 40-50 inch lbs. (4.4-5.6 Nm).
  10.  

1967-87 Chrysler Reduction Gear Starter

See Figures 10, 11 and 12

  1. Support the assembly in a vise equipped with soft jaws; do not clamp. Care must be used not to distort or damage the die cast aluminum.
  2.  
  3. Remove the through-bolts and the end housing.
  4.  
  5. Carefully pull the armature up and out of the gear housing, then the starter frame and the field assembly. Remove the steel and the fiber thrust washer.
  6.  

On V8 engines the starting motors have the wire of the shunt field coil soldered to the brush terminal. The 6 cylinder engines have the four coils in series and do not have a wire soldered to the brush terminal. One pair of brushes is connected to this terminal, while the other pair is attached to the series field coils by means of a terminal screw. Carefully pull the frame and the field assembly up enough to expose the terminal screw and the solder connection of the shunt field at the brush terminal. Place two wooden blocks between the starter frame and gear housing to facilitate removal of the terminal screw and unsoldering of the shunt field wire at the brush terminal.

  1. Support the brush terminal with a finger behind it and remove the screw.
  2.  
  3. On the V8 engine starters, unsolder the shunt field coil lead from the brush terminal and the housing.
  4.  
  5. The brush holder plate with the terminal, the contact and the brushes is serviced as an assembly.
  6.  
  7. Clean the old sealant from around the plate and the housing, then remove the brush holder attaching screw.
  8.  



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Fig. Fig. 10: 1967-72 Reduction gear starter exploded view

  1. On the shunt type, unsolder the solenoid winding from the brush terminal, then remove the 11 / 32 in. (8.7mm) nut, the washer and the insulator from solenoid terminal.
  2.  
  3. Remove the brush holder plate with the brushes as an assembly.
  4.  
  5. Remove gear housing ground screw, then the solenoid assembly from the well. Remove the nut, the washer and the seal from starter (battery) terminal, then the terminal from plate.
  6.  
  7. Remove the solenoid contact and the plunger from solenoid, then the coil sleeve. Remove the solenoid return spring, the coil retaining washer, the retainer and the dust cover from the gear housing.
  8.  
  9. Release the snapring which locates the driven gear pinion shaft, then the front retaining ring. Push the pinion shaft rearward, then remove the snapring, the thrust washers, the clutch and the pinion, then the two shift fork nylon actuators.
  10.  
  11. Remove the driven gear and the friction washer. Pull the shifting fork forward and remove the moving core.
  12.  
  13. Remove the fork retainer pin and the shifting fork assembly. The gear housing with bushings is serviced as an assembly.
  14.  
  15. Brushes that are worn more than 1 / 2 the length of new brushes or are oil soaked, should be replaced.
  16.  



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Fig. Fig. 11: 1973-78 Reduction gear starter

  1. When resoldering the shunt field and the solenoid lead, make a strong low resistance connection using a high temperature solder and a resin flux. Do not use acid or acid core solder. Do not break the shunt field wire units when removing and installing the brushes.
  2.  
  3. Do not immerse the starter clutch unit in a cleaning solvent. The outside of the clutch and the pinion must be cleaned with a cloth so as not to wash the lubricant from the inside of the clutch.
  4.  
  5. Rotate the pinion, the pinion gear should rotate smoothly and in one direction only. If the starter clutch unit does not function properly or if the pinion is worn, chipped or burred, replace the starter clutch unit.
  6.  
  7. Inspect the commutator and the brush contact surface when the starter is assembled, for flat spots, out of roundness or excessive wear.
  8.  
  9. Reface the commutator (if necessary), by removing only a sufficient amount of metal to provide a smooth, even surface.
  10.  
  11. Using light pressure, clean the grooves of the face of the commutator with a pointed tool, neither remove any metal nor widen the grooves.
  12.  

To assemble:
  1. Install the fork retainer pin and the shifting fork assembly.
  2.  
  3. Pull the shifting fork forward and install the moving core. Install the driven gear and the friction washer.
  4.  



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Fig. Fig. 12: 1979-87 Reduction gear starter

  1. Push the pinion shaft rearward, then install the snapring, the thrust washers, the clutch and the pinion, then the two shift fork nylon actuators. Install the snapring which locates the driven gear pinion shaft, then the front retaining ring.
  2.  
  3. Install the solenoid return spring, the coil retaining washer, the retainer and the dust cover from the gear housing. Install the coil sleeve then the solenoid contact and the plunger on the solenoid.
  4.  
  5. Install the solenoid assembly then the gear housing ground screw, in the well. Install the nut, the washer and the seal on the starter (battery) terminal, then the terminal on the plate.
  6.  
  7. After lubricating the plates with a small amount of SAE 10W30 engine oil, they should have about 1 / 16 in. (1.5mm) side movement to insure proper pinion gear engagement.
  8.  
  9. Install the brush holder plate with the brushes as an assembly.
  10.  
  11. On the shunt type, solder the solenoid winding from the brush terminal, then install the 11 / 32 in.
  12.  

(8.7mm) nut, the washer and the insulator on solenoid terminal.

  1. Install the brush holder attaching screw.
  2.  
  3. Install the brush holder plate with the terminal, the contact and the brushes as an assembly.
  4.  
  5. On the V8 engine starters, solder the shunt field coil lead from the brush terminal and the housing.
  6.  
  7. Support the brush terminal with a finger behind the terminal and install the screw.
  8.  

On V8 engines the starting motors have the wire of the shunt field coil soldered to the brush terminal. The 6 cylinder engines have the four coils in series and do not have a wire soldered to the brush terminal. One pair of brushes is connected to this terminal, while the other pair is attached to the series field coils by means of a terminal screw. Carefully pull the frame and the field assembly up enough to expose the terminal screw and the solder connection of the shunt field at the brush terminal. Place two wooden blocks between the starter frame and gear housing to facilitate installation of the terminal screw and soldering of the shunt field wire at the brush terminal.

  1. Install the steel and the fiber thrust washer. Carefully push the armature down and into the gear housing, then the starter frame and the field assembly.
  2.  
  3. Install the end housing and the through-bolts.
  4.  
  5. Install the starter.
  6.  

1978-79 Diesel Reduction Gear Starter

  1. Remove the through-bolts and brush plate screws from the end plate and remove the end plate.
  2.  
  3. Pull up on the brush springs and remove the brushes from their holders.
  4.  
  5. Remove the brush plate from the commutator.
  6.  
  7. Remove the nut and washer from the solenoid field terminal and pull the field lead off the terminal.
  8.  
  9. Remove the field frame assembly from the center bracket.
  10.  
  11. Discard the seal ring from between the field frame assembly and center bracket.
  12.  
  13. Remove the Phillips screws securing the solenoid to the drive end housing. Lift the rear of the solenoid up and pull it out to disengage the plunger from the shift fork.
  14.  
  15. Remove the solenoid from the drive end housing.
  16.  
  17. Remove the bolt securing the center bracket to the drive end housing.
  18.  
  19. Separate the center bracket and armature from the drive end housing.
  20.  
  21. Separate the armature from the center bracket.
  22.  
  23. Pry the gasket out of the front of the drive end housing.
  24.  
  25. Remove the metal retainer and plastic spacer from the front of the shift fork.
  26.  
  27. Remove the Phillips screws holding the reduction gear bearing retainer in the drive end housing. Pull forward on the reduction gear, then remove the gear and shaft assembly, shift fork pivot pin retainers, shift fork, and pivot pin from the drive end housing.
  28.  
  29. Disengage the shift fork from the clutch assembly and remove the pivot pin retainers and pivot pin.
  30.  
  31. Press back the retaining collar on the reduction gear shaft and remove the snapring from the end of the shaft.
  32.  
  33. Remove the collar, shift assembly, reduction gear bearing retainer and the reduction gear and shaft assembly.
  34.  
  35. Remove the snapring from the end of the clutch assembly, then remove the clutch spring and spring retainer.
  36.  
  37. Drive the welch plug out of the back end of the drive end housing.
  38.  

To assemble:
  1. Drive the welch plug into the back end of the drive end housing.
  2.  
  3. Install the clutch spring and spring retainer, then install the snapring on the end of the clutch assembly and .
  4.  
  5. Assemble the collar, shift assembly, reduction gear bearing retainer and the reduction gear and shaft assembly.
  6.  
  7. Install the snapring on the end of the reduction gear shaft and secure it with the collar.
  8.  
  9. Install the shift fork over the clutch assembly, then install the pivot pin retainers and pivot pin.
  10.  
  11. Install the reduction gear and shaft assembly, shift fork pivot pin retainers, shift fork, and pivot pin in the drive end housing. Install the Phillips screws holding the reduction gear bearing retainer in the drive end housing.
  12.  
  13. Install the metal retainer and plastic spacer in the front of the shift fork.
  14.  
  15. Install a new gasket in the front of the drive end housing.
  16.  
  17. Install the armature in the center bracket.
  18.  
  19. Engage the armature pinion gear with the reduction gear and install the center bracket in drive end housing. Secure it with the bolt and washer.
  20.  
  21. Engage the solenoid plunger and shift fork, then install the solenoid on the drive end housing. Make sure that the spacers are positioned behind the solenoid.
  22.  
  23. Install the Phillips screws securing the solenoid to the drive end housing.
  24.  
  25. Install a new seal ring on the center bracket. Make sure that the assembly is oriented to permit connection to the solenoid terminal.
  26.  
  27. Install the field frame assembly on the center bracket.
  28.  
  29. Install the field lead on the terminal.
  30.  
  31. Install the brush plate from the commutator.
  32.  
  33. Pull up on the brush springs and install the brushes in their holders.
  34.  
  35. Install the end plate.
  36.  

1988 Nippondenso Starter

See Figure 13

  1. Position the assembly in a suitable holding fixture. Remove the rubber boot from the field coil terminal. Remove the nut from the field coil terminal stud. Remove the field coil terminal from the stud.
  2.  
  3. Remove the through-bolts. Remove the splash shield. Remove the end shield screws from the brush plate. Remove the starter end shield.
  4.  
  5. Slide the brushes from their holders. Pry the retaining springs back for access. Remove the brush plate.
  6.  
  7. Slide the armature out of the starter housing. Remove the starter housing from the gear housing. Remove the solenoid terminal cover.
  8.  
  9. Remove the solenoid terminal nut and washer. Remove the battery terminal nut and washer. Remove the solenoid terminal assembly from the terminal posts.
  10.  
  11. Remove the solenoid terminal from the insulator. Remove the battery terminal from the insulator.
  12.  
  13. Remove the solenoid cover screws from the solenoid assembly. Remove the solenoid cover. Remove the seal. Remove the solenoid plunger from the housing. Remove the plunger spring.
  14.  
  15. Remove the gear housing to solenoid retaining screws. Separate the gear housing from the solenoid housing.
  16.  



Click image to see an enlarged view

Fig. Fig. 13: Nippondenso starter

  1. Remove the reduction gear and clutch assembly from the gear housing.
  2.  
  3. Remove the reduction gear, pinion gear, retainer and roller assembly from the gear housing.
  4.  
  5. Inspect and clean all parts, as required. Repair or replace defective parts as required. Brushes that are worn more than one-half the length of new brushes, or are oil soaked should be replaced.
  6.  

To assemble:
  1. Install the reduction gear, pinion gear, retainer and roller assembly in the gear housing.
  2.  
  3. Install the reduction gear and clutch assembly in the gear housing.
  4.  
  5. Join the gear housing to the solenoid housing. Install the gear housing to solenoid retaining screws.
  6.  
  7. Install the plunger spring then the solenoid plunger in the housing.
  8.  
  9. Install the seal.
  10.  
  11. Install the solenoid cover.
  12.  
  13. Install the solenoid and battery terminal on the insulators.
  14.  
  15. Install the nut and washers to the solenoid and battery terminals.
  16.  
  17. Install the solenoid terminal assembly on the terminal posts and the terminal cover.
  18.  
  19. Install the starter housing from the gear housing.
  20.  
  21. Slide the armature into the starter housing.
  22.  
  23. Install the brush plate. Slide the brushes into their holders.
  24.  
  25. Install the starter end shield. Install the end shield screws from the brush plate. Install the splash shield and the through bolts.
  26.  
  27. Install the field coil terminal from the stud.
  28.  
  29. Install the nut from the field coil terminal stud.
  30.  
  31. Install the rubber boot from the field coil terminal.
  32.  

 
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