1. Remove the starter solenoid field coil lead:

•	Remove the field coil nut (2)

•	Remove the field coil lead

2. Remove the solenoid screws (3).
3. Remove the solenoid.



4. Remove the commutator end shield bolts (2).
5. Remove the commutator end shield washers.



6. Drive the shift lever sealing plate (1) out of the armerature frame.
7. Remove the shift lever plunger from the housing.
8. Pry out the shift lever guide from the drive pinion housing.
9. Remove the drive pinion housing.



10. Pull out the drive pinion with the gear reduction unit.



11. Lightly tap on the armature shaft in order to unseat the commutator end frame from the armature frame.
12. Remove the armature with the commutator end frame and brush holder (1) from the armature frame.



13. Remove the commutator end frame cover screws (2).
14. Remove the commutator end frame cover (1).
15. Remove the armature E clip (3).



16. Remove the following components from the armature:

•	The washer (5)

•	The seal (4)

•	The commutator end frame (3)

•	The thrust washer (2)




17. Remove the brush holder plate (2) using a piece of pipe or a socket (1) about 32.0 mm (1.25 in) in order to retain the brushes in the plate.



18. Drive the collar from the drive gear retainer using a deepwell 14 mm socket.
19. Remove the retainer (1).
20. Remove the collar (2) and the starter drive (3) from the gear reduction unit.
21. Seperate the shift lever legs in order to remove the lever from the starter drive gear (4).



22. Remove the gear reduction unit shield from the housing.



23. Remove the field coils (1) from the armature frame:

•	Remove the retainer.

•	Using a drift, drive the field coils rearward in order to remove.

Notice: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation.

1. Clean all starter motor parts, wiping dry with a clean shop cloth.
2. Test the starter drive pinion:

•	Inspect the action: the starter drive should turn freely in the overrunning direction and lock up in the drive direction.

•	Inspect the teeth for any chips, cracks, or excessive wear:

-	Badly chipped teeth may indicate chipped flywheel teeth.

-	Replace the flywheel as needed.

•	Clean the pinion, but do not lubricate.

3. Inspect the armature commutator:

•	Clean as needed using a 400 grit polishing cloth.

•	Machine the commutator surface of the armature if the surface is rough.

Specification
Commutator diameter (min.): 31.20 mm (1.228 in).

•	Inspect the points where the conductors join the commutator bars in order to ensure proper connections. (A burned commutator bar is usually evidence of a poor connection.)

4. Inspect the brushes and the brush holders:

•	Inspect the brush length.

Specification
Brush length (min.): 8.00 mm (0.315 in)

•	Replace as needed.

•	Inspect that the brush holders are clean and the brushes are not binding in the holders.

•	Inspect the brush spring tension between the brushes and the commutator. Replace the springs if distorted or discolored.




5. Test the armature for shorts:

•	Place the armature on a growler.

•	Hold a hacksaw over the core while rotating the armature.

•	If the saw blade vibrates, the armature is shorted and must be replaced.

6. Test the armature winding for a short to ground:

•	Hold self powered test light probes to the core and the corresponding commutator lamination.

•	If the test lamp lights, replace the armature.




7. Test the brush holder (1) for a short:

•	Using a self powered test light, hold the probes on the negative and positive brush holders.

•	If the test lamp lights, replace the brush holder.

1. Drive the bearing from the housing (1) using a suitable drift.



2. Press the new bearing into the housing (2) using a suitable size driver and a press.

1. Soak the new bushing (2) in oil for at least 1/2 hour before installation.
2. Place a suitable size socket under the housing.
3. Use a suitable size driver (1) in order to drive the bushing from the housing.
4. Press in the new bushing using a suitable size driver and a press.

1. Install the field coils (1) in the armature frame:

•	Use a soft drift in order to seat the field coils in the armature frame.

•	Install the retainer.




2. Install the gear reduction unit shield to the armature frame.



3. Seperate the shift lever legs (4) in order to install the lever to the starter drive.
4. Install the starter drive gear (3) and the retainer collar to the gear reduction unit.
5. Install the starter drive gear retainer.
6. Snap the starter drive gear retainer collar onto the retainer using a plastic tool.



7. Install the brush holder plate (2) to the armature using a piece of pipe or a socket (1) about 32.0 mm (1.25 in) in order to retain the brushes.



8. Install the following components to the armature:

•	The thrust washer (2)

•

The C(3)

•	The seal (4)

•	The washer (5)




9. Install the armature E clip (3).
10. Install the commutator end frame cover (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

11. Install the commutator end frame cover screws (2).

Tighten
Tighten the screws to 1.8 N·m (16 lb in).




12. Install the armature with the brush holder, lightly tap the brush holder (1) in order to seat in the armature frame.



13. Install the starter drive gear with the gear reduction unit.
14. Install the drive end frame.
15. Push the shift lever guide into the drive end frame.
16. Install the shift lever plunger to the solenoid housing.



17. Push the shift lever sealing plate (1) into the housing.



18. Install the commutator end washers.
19. Install the commutator end bolts (2) to the starter motor.

Tighten
Tighten the bolts to 5 N·m (44 lb in).




20. Install the solenoid.
21. Install the solenoid screws.

Tighten
Tighten the screws to 5 N·m (44 lb in).

22. Install the field coil lead to the solinoid.
23. Install the field coil lead nut (2).

Tighten
Tighten the nut to 8 N·m (71 lb in).

24. Bench test the starter operation.