REMOVAL & INSTALLATION
- Disconnect the battery cable.
- Raise the car to a convenient working height.
Starter removal on certain models may necessitate the removal of the frame support. This support runs from the corner of the frame to the front crossmember. To remove the support, first loosen the mounting bolt that attaches the support to the corner of the frame. Then, loosen and remove the mounting bolt that attaches the support to the front crossmember and swing the support out of the way. Install the support in the reverse of the removal steps.
- Disconnect all wiring from the starter solenoid. Replace each nut as the connector is removed, as thread sizes differ from connector to connector. Note or tag the wiring positions for installation.
- Remove the front bracket from the starter and the two mounting bolts. On engines with a solenoid heat shield, remove the front bracket upper bolt and detach the bracket from the starter.
- Remove the front bracket bolt or nut. Lower the starter front end first, and then remove the unit from the car.
- Reverse the removal procedures to install the starter. Tighten the two mounting bolts to 25-35 ft. lbs.
See Figures 1 and 2
- Disconnect the field coil straps from the solenoid.
- Remove the through bolts, and separate 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, onto 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, then slide the starter drive onto the shaft [cf2]with the pinion facing outward. Slide the retainer onto the shaft [cf2]with the 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 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 onto 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 the clutch assembly into the drive housing, engaging the solenoid shift lever with the clutch, and positioning the front of the 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. [cf2]Work slowly and carefully to prevent damaging the starter brushers.
- Lubricate the bushing in the commutator end frame with a silicone lubricant, place the leather brake washer onto the armature shaft, then slide the commutator end frame over the shaft and into position against the field frame. Line up the bolt holes, 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 improper engagement of starter pinion to 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 shift lever, inspect, and replace worn parts.
- Disassemble the starter by following Steps 1 and 2 of the "Drive Replacement" procedure earlier in this section.
- Replace the brushes one at a time to avoid having to mark wiring. For each brush: remove the brush holding screw; remove the old brush and position the new brush in the same direction (large end toward center of field frame; position wire connector on top of brush, line up holes, and reinstall screw. Make sure screw is snug enough to ensure good contact.
- Reassemble starter according to Steps 10-13 of the previous "Drive Replacement" procedure.
- Remove the screw and washer from the motor connector strap terminal.
- Remove the two solenoid retaining screws.
- Twist the solenoid housing clockwise to remove the flange key from the keyway in the housing. Then, remove the housing.
- To re-install the unit, place the return spring on the plunger and place the solenoid body on the drive housing. Turn counterclockwise to engage the flange key. Place the two retaining screws in position and install the screw and washer which secures the strap terminal. Install the unit on the starter.
See Figures 5 through 23