d.  Drive  Assembly. (a)   See   figure   14-15   for   adjustments. (1)  Smooth  burrs,  nicks  and  rough  spots  on splines  and  pinion  teeth  using  a  fine  stone  or  crocus cloth   dipped   in   cleaning   solvent,   Federal   Specification P-D-680. (2)   Smooth   rough   spots,   scoring,   scratches   and nicks  on  inside  bore  of  sleeve  bearings  and  all  sur- faces  of  bronze  bearings  using  crocus  cloth  dipped  in cleaning    solvent,   Federal   Specification   P-D-680. e.   Solenoid   Assembly   Repair. (1)  Check  relay  windings  for  shorts  or  grounds with   ohmmeter. Replace  relay  if  windings  are  de- fective. (2)  Replace  relay  if  contact  assembly  shows  de- fects  such  as  warpage,  cracks,  or  broken  springs. (3)  Minor  burns  or  pits  on  contact  surfaces are   permissible. If   conditions   are   severe,   replace relay.   Do   not   use   a   file   to   dress   severely   burned   or pitted   contact   surfaces. f.  Field  Coil  Assembly. (1)   Smooth   minor   scratches,   burrs,   and   nicks on  machined  surfaces  of  frame  using  fine  mill  file, (2)   Repair   damaged   threads   in   frame.   Repair damaged   threads   on   field   coil   terminal   stud. (3)   Replace   starter   assembly   if   field   coil   insul- ation   resistance   is   less   than   one   megohm. 14-30.   Reassembly   and   Adjustments. a. Reassembly. Reassemble   electric   starter   in reverse   order   of   disassembly.   See   figures   14-11 through   14-13. b.   Adjustments. Perform   the   following   adjust- ments   during   reassembly. (1)  Solenoid  relay  plunger  shaft. (a)  See  figure  14-14.  Connect  12  Vdc across   relay   terminals   A   and   B.   Using   a   jumper, momentarily   connect   lead   terminal   C   to   terminal   A   to pull   the   relay   plunger   into   the   sealed   position.   Place a   straight   edge   across   the   relay   case   as   shown. Measure  the  distance  from  the  shaft  shoulder  to  the straight   edge. This  dimension  should  be  7/32  inch maximum   for   proper   assembly,   and   the   self-locking nut   will   be   tight   after   assembly.   Disconnect   power from  terminals  A  and  B. (b)  If  the  shoulder  to  straight  edge  dimen- sion   exceeds   7/32-inch,   the   self-locking   nut   must   be installed  and  tightened  until  the  end  of  the  nut  and  the end  of  the  shaft  are  flush  as  illustrated  in  figure  14- 14.  This  procedure  will  provide  adequate  overtravel. (b)   Remove   motor   field   coil   connector from   the   motor   switch   terminal   stud. (c)   Remove   ground   lead   assembly   connect- ing   motor   solenoid   relay   terminal   and   starter   ground terminal   stud. (d)   Remove   solenoid   relay   lead   assembly connecting   battery   switch   terminal   stud   and   battery solenoid   relay   terminal. (e)  Connect  a  24-volt  battery  supply  to battery   solenoid   relay   terminal   and   motor   solenoid relay   terminal. (f)   Momentarily   hold   a   jumper   lead   from the  motor  switch  terminal  stud  to  the  motor  solenoid relay    terminal. The  pinion  will  now  shift  into cranking  position  and  remain  so  until  the  battery is  disconnected. (g)  Push  pinion  back  toward  armature  to take  up  slack  movement. (h)  Check  for  0.020-  to  0.  050-inch  clear- ance   between   thrust   washer   and   pinion.   To   adjust, remove  inspection  plug  and  gasket.  Adjust  clear- ance  to  0.  020  to  0.  050  inch  by  turning  shaft  nut  as shown  in  figure  14-15. (i)   Connect   a   test   light   or   other   continuity checker   between   the   battery   switch   terminal   and motor   switch   terminal   stud. (j)  Connect  one  of  the  posts  of  a  24-volt battery   to   the   battery   solenoid   relay   terminal. Connect  the  other  battery  post  to  the  motor  solenoid relay    terminal. (k)  Place  a  0.  983-inch  spacer  block (figure  14-15)  between  the  pinion  and  thrust  washer and  momentarily  hold  a  jumper  lead  from  the  motor switch   terminal   stud   to   the   motor   solenoid   relay terminal. The  pinion  will  now  shift  against  the spacer  block  and  remain  so  until  the  jumper  lead  is disconnected.  The  motor  must  not  run.  The  motor must  run  when  the  distance  between  the  pinion  and thrust  washers  is  0.  500  inch. (1)  An  open  circuit  should  be  indicated  be- tween   the   battery   switch   and   motor   switch   terminals. If   continuity   exists,   decrease   the   pinion   clearance ((a)  above)  to  the  minimum  limit  of  0.020  inch  and recheck  to  make  sure  an  open  circuit  now  exists. (m)  Disconnect  battery  and  test  equipment and  install  motor  field  connector,  ground  lead  and solenoid   relay   lead. (n)   Install   inspection   plug   and   gasket, 14-31.   Test   and   Installation. (2)   Drive   assembly   pinion   clearance. 14-20