Starter Removal And Installation; Starting System Ovehaul; Starting System Cleaning And Inspection - Ford VSG-411 Service Manual

5-04
Starting System
5-04
REMOVAL AND INSTALLATION
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the cable and wires at the terminals on the
solenoid.
3. Remove the starter mounting bolts and remove the starter
assembly.
INSTALLATION
1. Position the starter assembly to the starter mounting plate and
start the mounting bolts.
2. Snug the starting motor mounting bolts while holding the
starter squarely against the mounting surface and fully insert-
ed into the pilot hole. Torque the mounting bolts.
3. Connect the cable and wires to the terminals on the solenoid.
Connect the battery ground
cabie.
OVERHAUL
DISASSEMBLY
1. Clamp starter motor in vise fitted with protective soft jaws.
Remove nut and washer retaining field winding cable to sole-
noid and remove cable from stud.
2. Remove solenoid by removing three screws.
3. Remove two screws retaining commutator end housing cap,
(Fig. 6) remove cap and rubber seal.
FIG. 6 End Housing Cap and Armature Shims
A- Retaining screw D - Shims
B -
Housing Cap
C - Screwdriver
F - " C" clip
- Armature shaft
4. Wipe grease from armature shaft, and remove "C" clip and
shims from armature end.
5. Remove through bolts or two nuts and washers and lift off
commutator end housing.
6. Remove brushes from brush holder assembly by carefully
lifting brush retaining/tensioning springs clear and sliding
brushes from their holder. Remove brush holder assembly.
7. Separate drive end housing and armature assembly from
frame by tapping apart.
8. Remove rubber insert from drive end housing. Remove actu-
ating arm pivot retaining nut and slide pivot pin from housing.
9. Withdraw armature assembly, complete with actuating arm,
from drive end housing. Unhook actuating arm from drive
pinion flange.
10. To remove drive pinion assembly from armature shaft use a
suitably dimensioned tube to separate thrust collar from over
"C" clip, (Fig. 7).
Remove "C" clip from its groove and slide thrust collar and
drive pinion assembly off armature shaft.
FIG. 7 Using a Suitably Dimensioned Tube
Separate Thrust Collar From " C" Clip Ring.
A- Thrust Collar
CLEANING AND INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Do not wash the drive because the solvent will wash out the
lubricant, causing the drive to slip. Use a brush or com-
pressed air to clean the drive, field coils, armature, com-
mutator, armature shaft front end plate, and rear end housing.
Wash all other parts in solvent and dry the parts.
Inspect the armature windings for broken or burned insulation
and unsoldered connections.
Check the armature for open circuits and grounds.
Inspect the armature shaft and the two bearings for scoring
and excessive wear. If the commutator is rough, turn it.
Check the brush holders for broken springs and the insulated
holder for shorts to ground. Replace the brushes if worn.
Check the brush spring tension.
Inspect the field coils for burned or broken insulation and
continuity. Check the field brush connections and lead insula-
tion. A brush kit is available. All other assemblies are to be
replaced rather than repaired.
Examine the wear pattern on the starter drive teeth. The pinion
teeth must penetrate to a depth greater than l/2 the ring gear
tooth depth (Figure 9, to eliminate premature ring gear and
starter drive failure.
Replace starter drives and ring gears with milled, pitted or
broken teeth or that show evidence of inadequate engagement
(Figure 9).