Starter Motor Assembly; Pinion And Ring Gear Wear Patterns Diagram - Ford VSG-411 Service Manual

5-06
Starting System
5-06
NORMAL WEAR PATTERN
SMALLWEARPATTERN
MILLED CONDITION-
EXCESSIVE WEAR ON
2 OR 3 TEETH
MILLED TOOTH-METAL
MILLED GEARS
J 1372-A
FIG. 9 Pinion and Ring Gear Wear Patterns
ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
Slide drive pinion assembly and thrust collar on to armature
shaft. Fit "C" clip into its groove in armature shaft and then
draw thrust collar over "C" clip.
Connect actuating arm on to drive pinion flange. Align armature
and actuating arm to drive end housing and couple up compo-
nents Install actuating arm pin and secure with retaining nut.
Install rubber insert into drive end housing.
Guide frame over armature and abut to drive end housing and
tap home.
Position brush holder over end of armature. Align location
"cut-out" in brush holder with "loop" in field windings (Fig.
10). Brush will be positively located when through bolts are
installed.
Position four brushes in their respective brush holder locations
and retain with brush springs.
Guide commutator end housing into position, sliding rubber
insulator into commutator housing "cut-out", and locating two
through bolts through housing holes. Secure commutator end
housing with two nuts and washers or two through bolts as
applicable.
Slide armature in its bearings, Fig. 11, to obtain maximum
possible protrusion of armature shaft at commutator bearing
end. Install sufficient shims on armature end play when "C"
clip is in place. Fit "C" clip (Fig. 6).
Place bearing cap seal in position on commutator housing,
smear a small quantity of lithium based grease on end of
armature shaft and refit bearing cap, securing with two screws
(Fig. 6).
FIG. 10 Position Brush Holder
A - Field Winding Loops
B- Location Cut-Outs
10. Smear lithium based grease onto solenoid armature hook and
then locate hook onto actuating arm in drive end housing.
Ensure solenoid armature return spring is correctly positioned
and then guide solenoid body over armature, Fig. 12. Align
body with drive end housing and install retaining screws.
11. Reconnect field winding cable to solenoid and install retaining
nut.