Brush Replacement; Armature Replacement - Ford LSG 875 Service Manual

5-09
STARTING SYSTEM
5-09
DISASSEMBLY AND ASSEMBLY (Continued)
BRUSH REPLACEMENT
Replace the starter brushes when they are worn
to 6.35mm (l/4 inch). Always install a complete set
of new brushes.
I. Remove the two through bolts from the starter
frame.
2. Remove the brush end plate, brush springs
and brushes from the holder.
3.
Remove the ground brush attaching screws or
rivets from the frame and remove the brushes.
4. Cut the insulated brush leads from the field
coils, as close to the field connection point as
possible.
5. Check the plastic brush holder for cracks or
broken mounting pads. Replace if necessary.
6. Position the new insulated field brushes lead
on the field coil connection. Position and
crimp the clip provided with the brushes to
hold the brush lead to the connection. Solder
the lead, clip, and connection together, using
a 300 watt iron and rosin core solder.
7. Install the ground brush leads to the frame
with the attaching screws or rivets.
8. Install brush holder and insert brushes in hold-
er and install brush springs. Positive brush
leads should be positioned in their respective
slots in the brush holder to prevent potential
grounding.
9. Install the brush end plate. Be sure end plate
insulator is positioned properly on the end
plate.
10. Install the two through bolts to the starter
frame and tighten to 6.21-8.47 Nom (55-75 in-
lb) .
11. Secure the starter in a vise and connect the
starter to a battery to check its operation.
ARMATURE REPLACEMENT
1. Remove starter drive plunger lever cover re-
tainer screw and remove cover.
2. Remove the through bolts, the drive end
housing, plunger lever and the drive plunger
lever return spring, brush end plate. Remove
brushes and lift out brush holder.
3. Remove the pivot pin retaining the starter
gear plunger lever.
4. Remove the armature. If the starter drive gear
assembly is being reused, remove the stop
ring from the end of the armature shaft, and
remove the drive.
5. Place the drive gear assembly on the new
armature with a new stop ring.
6. Install the armature in the starter frame.
7. Position the drive gear plunger lever to the
frame and drive gear assembly.
8. Partially fill the drive end housing bearing bore
with Grease ESB-MlC.63A or equivalent (ap-
proximately l/4 full). Position the drive plunger
lever return spring, the drive end housing to
the starter frame. Be sure that the stop ring
retainer is seated properly in the drive
housing.
9. Install brush holder and insert brushes in hold-
er and install brush springs. Positive brush
leads should be positioned in their respective
slots to prevent grounding.
10. Install the brush end plate (be certain end
plate insulator is positioned properly on end
plate).
11. Install the two through bolts to the starter
frame and tighten to 6.21-8.47 Nom (55-75 in-
lb). Install pivot pin.
12. Install starter drive plunger lever cover and
tighten retaining screw.
13. Check the starter no-load current draw.