Starters - MOTORCRAFT: Overhaul: Reassembly
- Install starter terminal, insulator, washers and retaining nut.NOTE: Position slot in screw perpendicular to frame end surface.
Position coils and pole pieces (with coil leads in terminal screw slot), install retaining screws. As screws are tightened, strike frame several times with soft faced hammer to seat and align pole shoes, then stake screws.
- Install solenoid coil and retainer and bend tabs to retain coils to frame. Solder field coils and solenoid wire to starter terminal using rosin core solder. Check for continuity and grounds in assembled coils. Position new insulated brush leads on field coil terminal (use clip provided with brushes to hold brush lead to terminal), solder lead, clip, and terminal with rosin core solder.
- Position solenoid coil ground terminal over nearest ground screw hole, place both ground brushes into starter frame and install retaining screws. Position commutator end plate on frame with end plate boss in frame slot. Apply thin coating of Lubriplate on armature shaft splines; install drive assembly on shaft and install new stop ring and retainer. Position fiber thrust washer on commutator end of armature and position armature in starter frame.NOTE: Fiber thrust washer is not used with molded commutator armatures.
- Position starter drive gear plunger lever to frame and starter drive assembly; install pivot pin. Partially fill drive end housing bearing (about 1/4 full) with grease. Position drive plunger lever return spring and drive end housing to frame; install and tighten through bolts to 55-75 INCH lbs. Do not pinch brush leads between plate and frame. Make sure stop ring retainer is seated properly in drive housing.
- Install brushes in brush holders, centering springs on brushes. Position drive gear plunger lever cover on starter and install brush cover band with a gasket. Tighten band retaining screw. Check starter no load current draw.