STARTER REASSEMBLY

PROCEDURE

  1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY

    1. A105368C01

      *1

      Planet Carrier

      *2

      Planet Carrier Shaft Sub-assembly

      Install the planet carrier shaft sub-assembly into the planet carrier.

    2. Install the washer onto the planet carrier shaft sub-assembly.

    3. A105363

      Using a screwdriver, install the snap ring onto the planet carrier shaft sub-assembly.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY

    1. A282530C01
      V100135

      High-temperature Grease

      Apply high-temperature grease to the spline of the starter clutch sub-assembly and planet carrier shaft sub-assembly.

    2. Install the starter clutch sub-assembly onto the planet carrier shaft sub-assembly.

    3. A104907C01

      *1

      Snap Ring

      *2

      Pinion Stop Collar

      Install the pinion stop collar and a new snap ring.

    4. A104906C01

      *1

      Planet Carrier Shaft Sub-assembly

      *2

      Snap Ring

      Using a vise, compress the snap ring.

    5. A033587C01

      *1

      Snap Ring

      *2

      Pinion Stop Collar

      While holding the starter clutch sub-assembly, lightly tap the planet carrier shaft sub-assembly and install the pinion stop collar onto the snap ring with a plastic hammer.

    6. A165831C01

      *1

      Drive Lever

      *2

      Starter Drive Housing Cover

      *3

      Starter Drive Housing

      *4

      Starter Clutch Sub-assembly

      *5

      Planet Carrier

      Install the starter clutch sub-assembly with planet carrier, drive lever and starter drive housing cover onto the starter drive housing.

    7. A282531C01
      V100135

      High-temperature Grease

      Apply high-temperature grease to the planet carrier.

    8. Install the 3 planetary gears onto the planet carrier.

  3. INSTALL STARTER ARMATURE ASSEMBLY

    1. A105361C01

      *1

      Starter Yoke Assembly

      *2

      Starter Armature Assembly

      Install the starter armature assembly into the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    1. A104844C01

      *a

      Spring

      *b

      Rubber

      *c

      Brush Holder

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

      Note:

      Do not overtighten the vise.

    2. While compressing the spring, install the starter brush holder assembly onto the starter armature assembly.

      Note:

      • Align the cutout of the starter yoke assembly with the rubber and install the starter brush holder assembly.

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

    3. A104843C01

      *1

      Washer

      *2

      Starter Commutator End Frame

      Install the starter commutator end frame onto the starter yoke assembly.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    4. Install the washer onto the starter commutator end frame.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    5. A282532C01

      *1

      Slotted Washer
      V100135

      High-temperature Grease

      Apply high-temperature grease to the slotted washer.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    6. Install the slotted washer.

    7. A104840

      Install the starter commutator end frame cover onto the starter commutator end frame with the 2 screws.

      1.4 N*m

      14 kgf*cm

      12 in.*lbf

  5. INSTALL STARTER YOKE ASSEMBLY

    1. A165827C01

      *1

      Planet Carrier

      *2

      Plate

      Install the plate onto the planet carrier.

    2. A165841C01

      *1

      Starter Drive Housing Cover

      *a

      Groove

      Align the groove of the starter yoke assembly with the starter drive housing cover.

    3. A165802

      Install the starter yoke assembly onto the starter drive housing with the 2 through bolts.

      4.8 N*m

      49 kgf*cm

      42 in.*lbf

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY

    1. A282533C01

      *1

      Drive Lever

      *2

      Plunger
      V100135

      High-temperature Grease

      Apply high-temperature grease to the hook.

    2. Install the plunger onto the drive lever.

    3. A165798

      Install the return spring onto the magnet starter switch assembly.

    4. Using a T25 "TORX" socket wrench, install the magnet starter switch assembly with the 3 screws.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

    5. A165796

      Connect the lead wire to the magnet starter switch assembly with the nut.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf