Starters - Direct Drive: Overhaul: Reassembly

Clean armature shaft and splines and lubricate with SAE 10-W oil or 30-W rust preventive oil, then install starter drive, stop collar (retainer), lock ring and spacer washer.

NOTE: Small diameter end of spacer washer should be in contact with lock ring inside collar.

Install shifting fork over starter drive spring retainer washer with narrow leg of fork toward commutator.

CAUTION: If fork is not properly positioned, it will restrict starter gear travel, causing a lockup in the clutch.

Install drive end pinion housing on armature shaft, indexing shifter fork with slot in housing, then install shifter fork pivot Pin. Install solenoid and boot assembly on field frame and tighten screws to 60-70 inch pounds. Install pinion housing and armature assembly into field frame so slot in housing indexes with locating tab projecting from solenoid base.

NOTE: Make sure shifting fork lever is inserted in solenoid plunger link.

Connect field coil leads at solenoid connector, then connect ground brushes and shunt wire terminal to field frame. Install brush holder ring assembly, indexing tang on ring in hole in field frame. Install brushes in brush holders.

CAUTION: Make sure field coil lead wires are properly enclosed behind brush holder ring and do not interfere with brush operation.

install thrust washers on end of armature shaft as required for correct endplay (see SPECIFICATIONS ), then install commutator end head and tighten through bolts to 40-50 inch pounds torque. Check starter drive gear pinion clearance.