REMOVAL & INSTALLATION
See Figures 1 and 2
In 1978, a gear reduction starter was introduced on some Canadian and United States models. The differences between the gear reduction and conventional starters are: the gear reduction starter has a set of ratio reduction gears while the conventional starter does not. The extra gears on the gear reduction starter make the starter pinion gear turn at about half the speed of the starter, giving the starter twice the turning power of a conventional starter.
- Disconnect the negative battery cable from the battery.
- Tag and disconnect the wiring at the starter, taking note of the positions for correct reinstallation.
- Remove the bolts attaching the starter to the engine and remove the starter from the vehicle.
- Install the starter in the reverse order of removal.
The starter solenoid is also know as the magnetic switch assembly.
- Disconnect the battery negative cable. Note routing and then disconnect all starter wiring.
- Note the location of the solenoid on top of the starter motor itself. If there is plenty of room, you can remove the solenoid with the starter mounted on the engine. Otherwise, remove the starter from the engine as described above.
- Remove the two through bolts from the starter front housing or gear case. Slide the solenoid to the rear slightly and grasp the shims which are mounted between the solenoid and front housing or gear case to keep them with the assembly. Then, pull the solenoid assembly upward and to the rear so as to disengage the front end of the solenoid plunger from the shift lever. Once the plunger is free, remove the solenoid assembly.
- Position the shims against the front of the unit, carefully lining up the through-bolt holes in them with those in the front of the solenoid body. If necessary, turn the plunger so the slot will fit over the vertical top of the shift lever, which is located in the front housing or gear case. Then, work the unit into position with the front end of the plunger near the top of the opening in the gear case or front housing.
- Position the opening in the front of the plunger over the shift lever and then lower the assembly so as to engage the plunger with the lever. Then, position the shims and solenoid so all bolt holes will line up.
- Install the through bolts and washers from in front of the gear case or front housing, if necessary turning the shims and solenoid assembly to line up the holes more perfectly. Torque the through bolts alternately and evenly to about 5 ft. lbs. (7 Nm).
- If necessary, reinstall the starter. Then, install the main battery cable and the two ignition cables, each to its correct terminal. Make sure the terminals are clean, and install the nuts and washers securely. Connect the battery negative cable and test the starter.
Non-Reduction Gear Type
- With the starter out of the vehicle, remove the bolts holding the solenoid to the top of the starter and remove the solenoid.
- To remove the brushes, remove the 2 through-bolts, the 2 rear cover attaching screws (some models) and the rear cover.
Remove the dust cover, E-ring and thrust washers from the armature shaft before the rear cover.
- Using a wire hook, lift the brush springs to separate the brushes from the commutator.
- Install the brushes in the reverse order of removal and reassemble the rear cover to the starter.
- Remove the starter, then the solenoid or magnetic switch.
- Remove the dust cover, E-ring and thrust washers.
- Remove the starter through-bolts and brush holder setscrews.
- Remove the rear cover. The rear cover can be pried off with a screwdriver; be careful not to damage the O-ring or gasket, if so equipped.
- Remove the starter housing, armature and brush holder from the center housing. They can be removed as an assembly.
- Using a wire hook on the spring, lift the spring then remove the positive side brush from its holder. The positive brush is insulated from the brush holder and its lead wire is connected to the field coil.
- Using a wire hook on the spring, lift the spring and remove the negative brush from the holder.
- Replace all the brushes in the starter assembly.
- Insert the new brushes in the brush holder.
- Install the starter housing, armature and brush holder to the center housing.
- Install the brush holder setscrews, rear cover and starter through-bolts.
- Install the thrust washers, E-ring and dust cover.
- Install the solenoid or magnetic switch.
STARTER DRIVE REPLACEMENT
Non-Reduction Gear Type
- With the starter motor removed from the vehicle, remove the solenoid from the starter.
- Remove the 2 through-bolts at the rear cover but do not disassemble the entire starter. Mark the front gear cover with relationship to the yoke housing.
- Separate the front gear case from the yoke housing, then the shift lever from the armature, without removing the armature from starter assembly.
- Push the pinion stopper toward the rear cover, then remove the pinion stopper clip and the pinion stopper.
- Slide the starter drive from the armature shaft.
- Install the starter drive on the armature shaft.
- Install pinion stopper and stopper clip.
- Reassemble the front gear case to the yoke and the shift lever to the armature.
- Install the rear cover through-bolts.
- Install the solenoid or the magnetic switch.
- Remove the starter.
- Remove the solenoid and the torsion spring. Mark the front housing with relationship to the center housing.
- Remove the center housing-to-front housing bolts, then separate the front housing from the center housing. Do not disassemble the entire starter.
- Remove the pinion/reduction gear assembly from the armature shaft. Try not to disassemble the entire starter when removing the pinion/reduction gear. Do not disturb the brush assembly in the rear cover.
It may be necessary to remove the shift lever pivot pin, to disconnect the pinion/reduction gear assembly from the armature shaft.To install:
- Install the pinion/reduction gear assembly onto the armature shaft.
- Attach the front housing to the center housing, being careful to align the matchmarks, then fasten the retaining bolts.
- Install the solenoid and torsion spring.