Starter Overhaul: Disassembly

NOTE:  Refer to the Exploded View if needed during this procedure.

• 1. End Cover - Remove

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• 2. Armature Housing - Remove

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• 3. Armature - Remove

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• 4. Armature - Inspect

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  1. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

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  2. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with #500 or #600 sandpaper (B).

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  3. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.

  Commutator Diameter
  Standard (New):	28.0-28.1 mm (1.102-1.106 in)
  Service Limit:	27.5 mm (1.083 in)

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  4. Measure the commutator (A) runout: If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments. If the commutator runout is not within the service limit, replace the armature.

  Commutator Runout
  Standard (New):	0.02 mm (0.0008 in) max.
  Service Limit:	0.05 mm (0.0020 in)

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  5. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.

  Commutator Mica Depth
  Standard (New):	0.40-0.50 mm (0.0157-0.0197 in)
  Service Limit:	0.15 mm (0.0059 in)

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  6. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any of the segments, replace the armature.

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  7. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.

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  8. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

• 5. Brush Holder Assembly - Remove

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  1. Remove the Terminal (A)

  2. Remove the push nut (B), the contact spring (C), the moving contact (D), and the brush springs (E)

  3. Remove the brush holder assembly (F).

• 6. Brush Holder - Test

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  1. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.

• 7. Brush - Inspect

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  1. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.

  Brush Length
  Standard (New):	11.1-11.5 mm (0.437-0.453 in)
  Service Limit:	4.3 mm (0.169 in)

• 8. Planetary Gear - Inspect

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  1. Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged.

• 9. Internal Gear - Remove

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• 10. Switch Plunger, Switch Shaft, and Gear Plunger - Remove

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• 11. Overrunning Clutch - Inspect

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  1. Hold the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set

  2. Hold the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaft does not turn freely, replace the gear cover set

  3. If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.