Replace oil soaked or cracked electrical brushes (48), or if they are less than 0.656 inch (16.66 mm) in
Replace the helical springs (50) i the tension is under 2 pounds (0.9 kg) (see step (20), above).
Remove nicks or accumulated dirt from the plunger (12) or bore to the electrical solenoids B1L3 or B2L4
(13) that would interfere with free movement of the plunger.
Replace the electrical solenoids B L3or B2L4(13) if tests (see Operator and Organizational Maintenance
Manual) show it to be defective.
Replace the plunger spring (8) if it is warped or if the free length is less than 2.296 inches (58.32 mm).
Replace the shift lever shaft (17) if it is visibly worn or grooved.
Replace shaft lever (15) if the pin holes are worn or elongated or if the pads are visibly worn or deformed.
Remove slight burrs or nicks from the pinion teeth of the drive assembly (25). Replace the drive assembly
if the teeth are cracked or excessively worm, or the overrunning clutch is defective.
Assemble. During reassembly, keep all parts dean, and align all match-marks made during disassembly. Unless
otherwise instructed, torque all screws and bolts in accordance with Table 1-2. Reassemble the starter motor as
Lubricate the spacer washer (36, Figure 4-3), and flat washer (52) with a thin film of petrolatum V-V-P236,
and install them on the armature (63).
Soak new oil wicks (23 and 30) in SAE 20 motor oil, and install them in the lever housing (28) and stator
housing (21). Secure the wicks with the protective dust caps (22 and 29).
To aid in installation of starter housing (43) and electrical holder assembly (51) on the
armature (63), do not attempt to install the starter housing and electrical holder assembly with
electrical brushes loaded by the helical springs (50). Instead, position the electrical brushes
(48) in the electrical holder assembly (51) so that the tangs of the helical springs (50) rest
against the sides of the electrical brushes and hold the electrical brushes in retracted
position. Once the starter housing (43) and electrical brush holder assembly (51) has been
installed on the armature (63), the tangs of the helical springs (50) may be placed in their
normal positions on the electrical brushes (48), tensioning the electrical brushes against the
Install the protective dust cap (44) and a new preformed packing (35) on the starter housing (43), and
install the assembled housing and electrical holder assembly (51) over the commutator of armature (63).
See Figure 4-4. Thread the field coil (61, Figure 4-3) brush leads through the inspection holes in the field
frame (64) and install the armature (63) in the field frame. Secure the starter housing (43) to the field
frame (64) using the machine bolts (27).
Attach the brush leads to the brush holders using the field coil screws (59).
With the lip facing the housing lever bushing (32), install a new oil seal (34) in the lever housing (28).
Install a new preformed packing (35) on the lever housing (28), and install the lever housing on the field
frame (64) and secure with machine bolts (27).
Install a brake washer (33) over the shaft of armature (63), insert the shaft lever (15) into lever housing
(28), bit the shaft lever, and install the lever housing (28), taking care that the shaft lever is properly
positioned in the collar of the drive assembly.
Install preformed packings (14 and 16), install the shift lever shaft (17), and secure it with a new snap ring
Using a gasket (26), install the stator housing (21), drive housing screw (19) and internal housing bolts
(20). Cross-tighten the screws to 13 to 17 pound-feet (18 to 23 newton-meters).