STARTER DISASSEMBLY

PROCEDURE


  1. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A001WPR

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

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

      Note

      Do not overtighten the vise.

    3. A001VTJC01
      *1 Starter Commutator End Frame Assembly

      Remove the 2 through bolts and starter commutator end frame assembly from the starter yoke assembly.

  2. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A001WDKC01
      *1 Starter Brush Holder Assembly
      *a Spring
      *b Rubber

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

      Note


      • Do not pull on the rubber.

      • Use caution to prevent the spring from dropping.

    2. Remove the starter assembly from the vise.

  3. REMOVE RING GEAR


    1. Remove the starter yoke assembly from the starter drive housing assembly.

    2. A001SVEC01
      *1 Starter Drive Housing Assembly
      *2 Starter Yoke Assembly
      *a Ring Gear

      Remove the ring gear from the starter drive housing assembly or starter yoke assembly.

    3. A001XQXC01
      *a Sun Gear
      *b Planetary Gear

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

  4. REMOVE STARTER ARMATURE ASSEMBLY


    1. A001SO8C01
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly
      *a Starter Armature Ring

      Remove the starter armature ring from the starter yoke assembly.

    2. Remove the starter armature assembly from the starter yoke assembly.

  5. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A001WCM

      Using a T25 "TORX" socket wrench, remove the 2 screws that hold the magnet starter switch assembly to the starter drive housing assembly.

    2. A001TWG

      While lifting the rear of the magnet starter switch assembly, remove the hook from the pinion drive lever, then remove the magnet starter switch assembly.

  6. REMOVE PINION GEAR


    1. A001SC9C01
      *1 Planet Carrier Shaft Sub-assembly with Pinion Gear
      *2 Pinion Drive Lever
      *3 Starter Drive Housing Assembly
      *a Starter Drive Housing Cover

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

    2. Secure the planet carrier shaft sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A001UONC01
      *1 Pinion Stop Collar
      *2 Pinion Gear

      Using a screwdriver, move the pinion stop collar down to the pinion gear.

    4. A001UGQC01
      *1 Snap Ring
      *2 Pinion Stop Collar

      Using a screwdriver, remove the snap ring.

    5. Remove the pinion stop collar.

    6. A001U4RC01
      *1 Pinion Gear
      *2 Planet Carrier Shaft Sub-assembly

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

  7. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A001XDVC01
      *a Snap Ring Pliers

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

    2. A001XY0C01
      *1 Planet Carrier Shaft Sub-assembly
      *a Washer

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

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

    4. A001TDEC01
      *1 Planet Carrier Shaft Sub-assembly
      *a Clutch Gear Cover

      Remove the planet carrier shaft sub-assembly from the clutch gear cover.