Hummer H1 Service Manual page 805

12-34 Electrical System
CORE
SPRING
RUBBER
BOOT
Figure 12-64: Solenoid Components
Starter Assembly
1. Assemble washer, rubber boot, spring retainer, spring, and
spring retainer on core shaft and secure with snap ring
(Figure 12-61).
2. Place core shaft assembly in solenoid housing.
3. Install washer, spring, contact, washer and locknut on core
shaft.
4. Place gasket on cover and secure series winding lead to
lug with screw and washer (Figure 12-61).
5. Install cover and gasket on solenoid housing and secure
with four rubber washers and nut and lockwasher
assemblies.
6. Install negative brushes and positive brushes in brush
holders and retain with four springs (Figure 12-60).
7. Connect positive brush leads to field coil brackets with
two screws.
8. Connect negative brush leads to frame with copper
washers, screws, lockwashers, and nuts.
9. Cover negative lead screw heads with silicone adhesive
sealant.
10. Apply chassis grease to armature shaft, shift lever studs,
groove of clutch, and inside diameter of end plate
(Figure 12-63).
11. Place washer, end plate, and gasket on armature shaft.
12. Place washer, clutch, and pinion stop on armature shaft
and retain with snap ring. Position armature and shift lever
in position shown for installation (Figure 12-59).
13. Install shift lever on clutch with shift lever studs engaged
in clutch groove.
14. Start shift lever into pinion housing as armature is
positioned in large bore of pinion housing. Then install
screws through armature plate into pinion housing.
Tighten screws to 40 lb-in. (5 N•m) (Figure 12-59).
15. Insert pin through pinion housing and shift lever. Then
install two plugs in pinion housing (Figure 12-58).
4-1-00
_______________________________________________________
SOLENOID
CONTACT
HOUSING
SPRING
CORE
SHAFT
16. Install O-ring and gasket in pinion housing (Figure 12-66).
17. Coat end plate-to-frame screws with adhesive sealant.
CAUTION: As armature is inserted into frame assembly, care-
fully align brushes on commutator. Brushes chip and break
easily.
18. Align scribe marks on frame and pinion housing, and
install armature and pinion housing in frame assembly.
Install and tighten screws to 50 lb-in. (6 N•m).
19. Saturate felt wick with engine oil and install in end plate
(Figure 12-65).
SCRIBE
MARK
FRAME
ASSEMBLY
THRUST
WASHER(S)
Figure 12-65: Starter End Plate Installation
20. Install spacer and thrust washers on armature shaft.
21. Align scribe marks on end plate and frame and install end
plate. Tighten end plate screws to 25 lb-in. (3 N•m).
22. Coat threads of end plate screws with adhesive sealant.
23. Install end plate screws.
24. Check end play as described in following procedure.
25. Coat ribbed area of core shaft boot with lithium grease
(Figure 12-67).
26. Align end of core shaft in hole in shift lever and install
solenoid on frame. Tighten solenoid screws to 50 lb-in. (6
N•m).
27. Install core shaft nut. Tighten nut with socket, fabricated
tool, and hex wrench (Figure 12-55)
GASKET
SCRIBE
MARK
SPACER
FELT
WICK
END
PLATE
®