Never operate the starter motor more than 30 seconds at a time without pausing to allow it to cool for at least two minutes. Overheating, caused by excessive cranking, will seriously damage the starter motor.
REMOVAL & INSTALLATION
- Disconnect the negative (-) battery cable.
- Raise and support the vehicle safely with jackstands.
- Remove the starter rear bracket bolt (2.5L L4 engine (LR8) only).
- Disconnect all wires at the solenoid terminals. Note the color coding of the wires for installation.
- Remove the two starter-to-engine bolts and remove the starter through the area forward of the converter (bell) housing.
- Position the starter assembly into the converter (bell) housing and install any shims that were removed. Install the two starter-to-engine mounting bolts and torque to 32 ft. lbs. (43 Nm).
- Install the rear bracket (2.5L L4 engine (LR8) only).
- Install the heat shield, if so equipped.
- Lower the vehicle.
- Connect the battery and solenoid wire in the same location of removal.
- Reconnect the negative battery (-) cable.
While the starter is engaged, if a high pitch whine, low pitch whoop or rumble occurs, the starter may have to be aligned or serviced with the proper shims that can be purchased at the dealer or local parts distributor. Measure the distance between the pinion gear and the flywheel ring gear as shown in the following illustration.
- To remove the solenoid, remove the screw from the field coil connector and solenoid mounting screws. Rotate the solenoid 90° and remove it along with the plunger return spring.
- For further service, remove the two through-bolts, then remove the commutator end frame and washer.
- To replace the clutch and drive assembly proceed as follows:
- Remove the thrust washer or the collar from the armature shaft.
- Slide a 5 / 8 in. deep socket or a piece of pipe of suitable size over the shaft and against the retainer as a driving tool. Tap the tool to remove the retainer off the snapring.
- Remove the snapring from the groove in the shaft. Check and make sure the snapring isn't distorted. If it is, it will be necessary to replace it with a new one upon reassembly.
- Remove the retainer and clutch assembly from the armature shaft.
- The shift lever may be disconnected from the plunger at this time by removing the roll pin.
- On models with the standard starter, the brushes may be removed by removing the brush holder pivot pin which positions one insulated and one grounded brush. Remove the brush and spring and replace the brushes as necessary.
- On models with the smaller 5MT starter, remove the brush and holder from the brush support, then remove the screw from the brush holder and separate the brush and holder. Replace the brushes as necessary.
- Lubricate the drive end of the armature shaft and slide the clutch assembly onto the armature shaft with the pinion away from the armature.
- Slide the retainer onto the shaft with the cupped side facing the end of the shaft.
- Install the snapring into the groove on the armature shaft.
- Install the thrust washer on the shaft.
- Position the retainer and thrust washer with the snapring in between. Using two pliers, grip the retainer and thrust washer or collar and squeeze until the snapring is forced into the retainer and is held securely in the groove in the armature shaft.
- Lubricate the drive gear housing bushing.
- Engage the shift lever yoke with the clutch and slide the complete assembly into the drive gear housing.
- Install the shift lever pivot bolt and tighten.
- Install the solenoid assembly and apply sealer to the solenoid flange where the field frame contacts it.
- Position the field frame against the drive gear housing on the alignment pin using care to prevent damage to the brushes.
- Lubricate the commutator end frame and install the washer on the armature shaft. Slide the end frame onto the shaft and tighten the bolts. Make sure the bolts pass through the holes in the insulator.
- Connect the field coil connector to the solenoid terminal.
When the starter motor has been disassembled or the solenoid has been replaced, it is necessary to check the pinion clearance. Pinion clearance must be correct to prevent the buttons on the shift lever yoke from rubbing on the clutch collar during cranking.
- Check pinion clearance as follows:
- Disconnect the motor field coil connector from the solenoid motor terminal and insulate it carefully.
- Connect the (+) 12 volt battery lead to the solenoid motor terminal and the (-) lead to the motor frame.
- Flash a jumper lead momentarily from the solenoid motor terminal to the starter frame. This will shift the pinion into the cranking position and will remain until the battery is disconnected.
- Push the pinion back as far as possible to take up any movement and check the clearance with a feeler gauge. The clearance should be 0.25-0.35mm.
- Means for adjusting pinion clearance is not provided on the starter motor. If the clearance is not within specifications, check for improper installation or worn parts.