STARTER(w/o Stop And Start System) DISASSEMBLY

PROCEDURE

1. REMOVE MAGNET STARTER SWITCH ASSEMBLY

   1. 

      Remove the nut, and disconnect the field coil lead wire from terminal C.

   2. 

      Using a T25 "TORX" socket wrench, remove the 3 screws that hold the magnet switch to the starter drive housing assembly.

   3. Remove the magnet switch from the starter drive housing assembly.

   4. Remove the return spring from the magnet switch.

   5. 

      *1	Pinion Drive Lever
      *a	Plunger

      Remove the plunger from the pinion drive lever.

2. REMOVE STARTER YOKE ASSEMBLY

   1. 

      Remove the 2 through bolts and starter yoke assembly together with the starter armature assembly from the starter drive housing assembly.

   2. 

      *a	Planet Carrier
      *b	Plate

      Remove the plate from the planet carrier.

3. REMOVE STARTER BRUSH HOLDER ASSEMBLY

   1. 

      Secure the starter yoke assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

   2. Remove the 2 screws and starter commutator end frame cover from the starter commutator end frame.

   3. 

      *a	Slotted Washer

      Remove the slotted washer.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

   4. 

      *a	Washer
      *b	Starter Commutator End Frame

      Remove the washer from the starter commutator end frame.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

   5. Remove the starter commutator end frame from the starter yoke assembly.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

   6. 

      *1	Starter Brush Holder Assembly
      *a	Rubber
      *b	Spring

      Remove the starter brush holder assembly from the starter armature assembly.

      Note:

      • Do not pull on the rubber.

      • Use caution to prevent the starter armature assembly from dropping.

4. REMOVE STARTER ARMATURE ASSEMBLY

   1. 

      *1	Starter Yoke Assembly
      *2	Starter Armature Assembly

      Remove the starter armature assembly from the starter yoke assembly.

5. REMOVE STARTER CLUTCH SUB-ASSEMBLY

   1. 

      Remove the 3 planetary gears from the planet carrier shaft sub-assembly.

   2. 

      *1	Pinion Drive Lever
      *2	Starter Drive Housing Cover
      *3	Starter Drive Housing Assembly
      *4	Planet Carrier Shaft Sub-assembly with Starter Clutch Sub-assembly and Planet Carrier

      Remove the planet carrier shaft sub-assembly with starter clutch sub-assembly and planet carrier, pinion drive lever and starter drive housing cover from the starter drive housing assembly.

   3. 

      *1	Pinion Stop Collar
      *2	Starter Clutch Sub-assembly

      Using a screwdriver, move the pinion stop collar down to the starter clutch sub-assembly.

   4. 

      *1	Snap Ring
      *2	Pinion Stop Collar

      Using a screwdriver, remove the snap ring.

   5. Remove the pinion stop collar.

   6. 

      *1	Starter Clutch Sub-assembly
      *2	Planet Carrier Shaft Sub-assembly

      Remove the starter clutch sub-assembly from the planet carrier shaft sub-assembly.

6. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY

   1. 

      Using 2 screwdrivers, remove the snap ring from the planet carrier shaft sub-assembly.

   2. 

      Remove the washer from the planet carrier shaft sub-assembly.

   3. 

      *1	Planet Carrier
      *2	Planet Carrier Shaft Sub-assembly

      Remove the planet carrier shaft sub-assembly from the planet carrier.