- Remove the starter from the vehicle.
- Disconnect the lead wire from the solenoid switch.
- Remove the through-bolts from the end frame.
- Remove the yoke from the solenoid switch.
- Remove the mounting screws that hold the housing to the solenoid switch.
- Separate the solenoid switch from the housing.
- Installation is the reverse order of removal.
- Connect terminal S of starter switch to the positive terminal of the battery using a lead wire or equivalent.
- Connect the starter body to the negative terminal of the battery.
- If the switch assembly is working correctly, the pinion should be forced out. If the starter motor rotates, this is OK. Sometimes current will flow through the pull in coil to the motor and cause this.
- With the pinion forced outward, measure the pinion gap. It should be between 0.02-0.08 inch (0.5-2.0mm).
- Unfasten all connections.
- Disconnect the wire at terminal M , and attach a lead wire or equivalent between terminal M and the battery positive terminal.
- Connect a ground lead between the stator body and the negative terminal of the battery.
- If the switch assembly is functioning correctly, the pinion should return it its original position.