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Pinion Gap Adjustment Test

NOTE: To prevent starter from turning, disconnect field strap from terminal "M" for following test.
  1. Using a 12-volt battery, connect positive battery cable to terminal "S", and negative cable to starter body. See Figure . When negative battery cable is connected to starter body, solenoid should engage and kick pinion out.
    NOTE: DO NOT engage solenoid for more than 20 seconds at a time. If test must be repeated, wait 3 minutes between attempts.
  2. With pinion extended, measure gap between pinion and collar. Gap should be .02-.08" (.5-2 mm). See Fig 1 . If gap is not within specifications, add or subtract shims between solenoid and drive end housing as necessary. Reconnect solenoid terminal "M".
Fig 1: Checking Pinion Gap
G106398Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Starter
G92D03514Courtesy of FORD MOTOR CO.