REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Disconnect the battery cables at the battery.
- Raise the front of the vehicle to a convenient working height and support with jackstands.
- Disconnect the wiring from the starter solenoid. Replace each connector nut as the terminals are removed as the thread sizes differ between connectors. Note or tag the wiring positions to avoid improper connections during installation.
- Remove the front starter support bracket and the heat shield (if so equipped).
- Loosen the two main starter mounting bolts, support the starter and remove the bolts. Lower and remove the starter.
- Reverse the previous steps to install the starter. Torque the two main starter mounting bolts to 25-35 ft. lbs.
OVERHAUL - Drive Replacement
See Figure 4
- Disconnect the field coil straps from the solenoid.
- Remove the two starter through bolts. Separate the commutator end frame, field frame, drive housing, and armature from each other.
- Slide the two-piece thrust collar off of the end of the armature shaft.
- Slide a 5 / 8 " deep socket or a piece of pipe of suitable size over the drive end of the armature shaft and against the snap-ring retainer. Carefully tap the socket or pipe towards the armature to drive the retainer off of the snapring.
- Remove the snapring from the armature shaft. Be careful, as the snapring will distort rather easily. If the snapring is distorted after removal, it must be replaced.
- Slide the starter drive and retainer from the armature shaft.
- Lubricate the drive end of the armature shaft with silicone lubricant and slide the starter drive onto the shaft with the pinion gear facing away from the armature. Slide the retainer onto the shaft with the cupped portion facing away from the armature.
- Support the armature assembly in a vertical fashion with the drive end pointing upward. Position the snapring on the top of the shaft, and carefully place a block of wood on the snapring. Keep the snapring centered. Tap the block of wood to drive the snapring onto the shaft. Using a deep socket that will fit around the shaft without interference and yet contact the snapring, force the snapring downward into its groove on the shaft.
- Place the thrust washer on the shaft. Using two pairs of pliers as shown in the accompanying illustration, force the snapring retainer over the snapring and engage it with the thrust washer.
- Lubricate the drive housing bushing with silicone lubricant. Install the armature and clutch assembly into the drive housing, engaging the solenoid shift lever with the clutch, and positioning the front end of the armature shaft into the drive housing bushing.
- Apply a sealing compound (G.M. #1050026 or its equivalent) to the drive housing around the area where the field frame mates with the housing.
- Slide the field frame assembly over the armature and guide the brushes over the armature commutator. Continue to push the field frame until the frame mates to the drive housing. Work slowly and carefully to prevent brush damage.
- Lubricate the bushing in the commutator end frame with silicone lubricant, being careful not to get the lubricant on surrounding components.
- Place the leather washer onto the armature shaft and 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 two starter through bolts.
If replacement of the starter drive fails to cure improper engagement of the starter pinion to the flywheel, there are probably defective parts in the solenoid and/or shift lever. In this case, it would probably be best to take the starter assembly (incl. solenoid) where a pinion clearance check can be made. If the pinion clearance is incorrect, disassemble the solenoid and shift lever. Inspect these parts and replace as necessary.
- Disassemble the starter by following Steps 1 and 2 of the previous Drive Replacement procedure.
- Replace the brushes one at a time to avoid having to mark the wiring. For each brush: Remove the brush retaining screw and remove the old brush. Install the new brush in the same direction (large end towards the end of the field frame). Position the wire connector on the top of the brush, line up the holes and reinstall the screw. Make sure the screw is snug enough to ensure good contact.
- Reassemble the starter according to Steps 10-14 of the previous procedure.
See Figure 7
- Remove the screw and washer from the motor connector strap terminal.
- Remove the two solenoid retaining screws.
- Twist the solenoid clockwise to remove the solenoid flange key from the keyway in the housing. Remove the solenoid.
- Place the return spring on the plunger and place the solenoid body on the drive housing. Push the solenoid inward and turn counterclockwise to engage the flange key. Install and tighten the solenoid retaining screws and the screw and washer which secure the strap terminal.