Ford LSG 875 Service Manual page 154

5a-10 Starter, Permanent Magnet
5a-10
DISASSEMBLY AND ASSEMBLY (Continued)
3. Check commutator for runout. Inspect armature
shaft and two bearings for scoring and excessive
wear with Dial Indicator TOOL-420 1-C or
equivalent. If commutator is rough, or more than
0.12mm (.005 inch) out of round, it must be
replaced.
COMMUTATOR RUNOUT CHECK
DIAL INDICATOR
TOOL-4201 -C
" V" BLOCKS
J2711-1B
4. Examine gears, spline on driveshaft, and drive
pinion for chipped, broken or worn conditions.
Replace if required.
PINION AND RfNG GEAR WEAR PATTERNS
SMALL WEAR PAlTERN
MILLE D CONDITION
WEAR ON 2
EXCESSIVE
OR 3 TEETH
MILLED TOOTH-METAL BUILD-UP
WILL NOT PERMIT ENGAGEMENT
NORMAL WEAR PATTERN
MILLED GEARS
Assembly
1.
Install armature assembly in starter frame. Apply
a thin coating of ESF-M 1 C2 18-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).
2. 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.
3. Grease and install planet gears.
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). lighten solenoid bolts
to 5.1-9.6 Nom (45-85 in-lb).
7. Attach positive brush connector to solenoid
(bottom terminal). Tighten nut to 9-13 Nom
(80- 120 in-lb).