Pinion And Ring Gear Wear Patterns - Ford LRG-423 Service Manual

03-52
Auxiliary Systems
03-52
STARTER, PERMANENT MAGNET DISASSEMBLY AND ASSEMBLY (Continued)
COMMUTATOR RUNOUT CHECK
DIAL INDICATOR
TOOL4201-C
1B
4. Examine gears, spline on driveshaft, and drive
pinion for chipped, broken or worn conditions.
Replace if required.
NORMAL WEAR PAl7ERN
PINION AND RING GEAR WEAR PAlTERNS
WEAR ON 2 OR 3 TEETH
MILLED CONDITION EXCESSIVE
MlLtED TOOTH-METAL BUILD-UP
MILLED GEARS
PPD0045
Assembly
1. Install armature assembly in starter frame. Apply
a thin coating of ESF-MlC218-A Grease, or
equivalent low temperature grease, on both ends
of armature shaft and spline. Install brush
assembly ensuring brushes fit over commutator.
Apply grease to bearing bore in brush end plate.
Push back grommet onto frame and attach brush
end with brush plate screws. Tighten to 2.3-3.4
Nom (20-30 in-lb).
4. Apply grease into drive end housing bearing bore
(approximately one-quarter full). Install drive gear
assembly into housing, making sure to line up
bolt holes in gear assembly and housing. Place
gear retainer over gear assembly. Install housing
seal assembly into drive end housing.
5. Position starter frame to housing and install through-
bolts. Tighten to 5.0-9.5 Nom (45-84 in-lb).
6. Correctly position solenoid to housing ensuring
that solenoid plunger is attached through drive
lever (bottom solenoid terminal " M" should have a
metal strip attached to it). Tighten solenoid bolts
to 5.1-9.6 Nom (45-85 in-lb).
Apply grease to driveshaft spline and place
stationary gear assembly over driveshaft. Install
armature thrust washer and push C-ring onto
driveshaft. Place drive assembly onto shaft and
install stop ring and retainer. Attach drive lever to
drive assembly.
Grease and install planet gears.
7. Attach positive brush connector to solenoid
(bottom terminal). Tighten nut to 9-l 3 Nom
(80-I 20 in-lb).
8.
Check that starter no-load current draw is within
specification. Refer to Bench Tests.